Heat Exchanger Area Targeting

ENGM071 - Process and Energy Integration

Outline
• Capital Energy Trade-Offs
• Heat Exchanger Area Targeting
• Summary

2
Key steps of Pinch Technology
There are four key steps of pinch analysis in the design of
heat recovery systems for both new and existing processes:

1. Data Extraction from a PFD, which involves collecting

data for the process and the utility system

2. Targeting, which establishes targets for design in terms

of energy, number of units, area, etc. for best
performance

3. Design, where an initial Heat Exchanger Network is

established

4. Optimization, where the initial design is simplified and

Will be considered later
improved economically
3
Capital-Energy Trade-Offs

4
Capital Energy Trade-Offs

5
Energy Cost Targets as a Function of Δ𝑇𝑚𝑖𝑛
Energy
cost

Overall

Hot utility

Cold utility

Δ𝑇𝑚𝑖𝑛

Larger driving forces – higher energy consumption

6
 What About Capital Cost?
CAPITAL COST

Materials of Pressure
construction rating

No. of shells Equipment

type
No. of units HE Area
most significant factor

How to estimate HEN heat transfer area?

7
Heat Exchanger Area Targeting

8
Balanced Composite Curves
𝑇

Construct balanced composite curves (BCCs):

• Include all utilities
• Heat sources and sinks are in balance 9
Enthalpy Intervals
𝑇

7
Heat recovery occurs in 6
enthalpy intervals 3-5
5
4
3

2
1
Enthalpy intervals
𝐻

Slice the balanced CCs into enthalpy intervals through

points where the slope of either balanced CC changes
10
Heat Transfer Area for an Enthalpy
Interval
𝑇 𝑄 = 𝑈 ∙ 𝐴 ∙ Δ𝑇𝐿𝑀

Interval 𝑛

Assuming the same

overall heat transfer
Δ𝐻𝑛 coefficient U throughout
𝐴𝑛 = 𝑛
𝑈 ∙ Δ𝑇𝐿𝑀
Not true in the general case
since composite curves are
combinations of multiple
streams!

𝐻
1 Δ𝐻𝑛
Overall network area: 𝐴𝑁𝑒𝑡𝑤𝑜𝑟𝑘 = ෍ 𝑛
𝑈 Δ𝑇𝐿𝑀
𝑛 11
Heat Transfer Coefficients Revised
Heat exchange in a shell-and-tube HEX

The overall heat transfer coefficient is given by

1 1 1 𝑑𝑂 𝑑𝑂 𝑑𝑂 1 𝑑𝑂 1
= + + ln + ∙ + ∙
𝑈 ℎ𝑆 ℎ𝑆𝐹 2𝑘 𝑑𝑖 𝑑𝑖 ℎ 𝑇𝐹 𝑑𝑖 ℎ 𝑇

Film heat transfer coefficients (W ∙ m−2 ∙ K −1 ):

ℎ𝑆 – on the outside (shell-side) of tubes
Heat transfer across fluid films ℎ𝑆𝐹 – outside (shell-side) fouling coefficient
& fouling layers
ℎ 𝑇𝐹 – inside (tube-side) fouling coefficient
𝑄 = ℎ ∙ 𝐴 ∙ Δ𝑇
ℎ 𝑇 – on the inside (tube-side) of tubes
Heat transfer across tube wall
𝑑𝑇 𝑘 – thermal conductivity of the tube wall material
𝑄 = −𝑘 ∙ 𝐴 ∙
𝑑𝑟 (W ∙ m−1 ∙ K −1 ) 12
Heat Transfer Coefficients Revised
Heat exchange in a shell-and-tube HEX

The overall heat transfer coefficient is given by

1 1 1 𝑑𝑂 𝑑𝑂 𝑑𝑂 1 𝑑𝑂 1
= + + ln + ∙ + ∙
𝑈 ℎ𝑆 ℎ𝑆𝐹 2𝑘 𝑑𝑖 𝑑𝑖 ℎ 𝑇𝐹 𝑑𝑖 ℎ 𝑇
0 1
Assume that
a) there is no fouling
Heat transfer across fluid films b) tube walls are thin
& fouling layers c) and heat transfer through tube walls is fast
𝑄 = ℎ ∙ 𝐴 ∙ Δ𝑇
Heat transfer across tube wall 1 1 1
𝑑𝑇
≈ +
𝑄 = −𝑘 ∙ 𝐴 ∙
𝑈 ℎ𝑆 ℎ 𝑇
𝑑𝑟 13
Heat Transfer Area for an Enthalpy
Interval:
𝑇 𝑄 = 𝑈 ∙ 𝐴 ∙ Δ𝑇𝐿𝑀

Interval 𝑛

1 𝑞𝑖,𝑛 𝑞𝑗,𝑛
𝐴𝑛,𝑚𝑖𝑛 = 𝑛 ෍ + ෍
Δ𝑇𝐿𝑀 ℎ𝑖,𝑛 ℎ𝑗,𝑛
ℎ𝑜𝑡 𝑠𝑡𝑟𝑒𝑎𝑚𝑠 𝑖 𝑐𝑜𝑙𝑑 𝑠𝑡𝑟𝑒𝑎𝑚𝑠 𝑗

ℎ𝑖,𝑛 , ℎ𝑗,𝑛 – film transfer coefficients for hot stream 𝑖

and cold stream 𝑗 in enthalpy interval 𝑛

𝑞𝑖,𝑛 , 𝑞𝑗,𝑛 – enthalpy changes of hot stream 𝐻

𝑖 and cold stream 𝑗 in enthalpy interval 𝑛

14
Overall area target
𝑇
7
6

5
4
3

2
1

1 𝑞𝑖,𝑛 𝑞𝑗,𝑛
Network area: 𝐴𝑚𝑖𝑛 = ෍ 𝑛 ෍ + ෍
Δ𝑇𝐿𝑀 ℎ𝑖,𝑛 ℎ𝑗,𝑛
𝑖𝑛𝑡𝑒𝑟𝑣𝑎𝑙𝑠 𝑛 ℎ𝑜𝑡 𝑠𝑡𝑟𝑒𝑎𝑚𝑠 𝑖 𝑐𝑜𝑙𝑑 𝑠𝑡𝑟𝑒𝑎𝑚𝑠 𝑗

15
Example 1: Area Targeting
Calculate the area target for stream data in Table 1 where two hot streams
exchange heat against a single cold stream using Δ𝑇𝑚𝑖𝑛 = 10°C. The film heat
transfer coefficient h is constant and equal to 0.123 kW/m2K for all streams in all
heat exchangers

Table 1: Stream data for a three-stream problem

Supply temp. Target temp.

Stream CP / (kW/°C)
𝑇𝑆 /°C 𝑇𝑇 /°C

Hot (H1) 180 140 1.4

Hot (H2) 150 90 2.5

Cold (C1) 70 150 4

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STEP 1: Calculation of Energy Targets

Table 2: Temperature shifting for a three-stream problem

Supply temp. Target temp.

Stream 𝑇𝑆∗ /°C 𝑇𝑇∗ /°C
𝑇𝑆 /°C 𝑇𝑇 /°C

Hot (H1) 180 140 175 135

Hot (H2) 150 90 145 85

Cold (C1) 70 150 75 155

Δ𝑇𝑚𝑖𝑛 = 10°C

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STEP 1: Calculation of Energy Targets
σ 𝐶𝑃𝐶 −
Temperature Stream Δ𝑇𝐼𝑁𝑇𝐸𝑅𝑉𝐴𝐿 Δ𝐻𝐼𝑁𝑇𝐸𝑅𝑉𝐴𝐿 Surplus/
σ 𝐶𝑃𝐻
boundary Population (ᵒC) (kW) Deficit
(kW/ᵒC)
1
175ᵒ
20 –1.4 –28.0 Surplus
CP = 1.4

155ᵒ
10 2.6 26.0 Deficit
2
145ᵒ
CP = 2.5

10 0.1 1.0 Deficit

135ᵒ
CP = 4

50 1.5 75.0 Deficit

85ᵒ
10 4.0 40.0 Deficit
75ᵒ
3

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STEP 1: Calculation of Energy Targets

175ᵒ 0 kW 175ᵒ 114.0 kW

Δ𝐻 = −28.0 Δ𝐻 = −28.0
155ᵒ 28.0 kW 155ᵒ 142.0 kW

Δ𝐻 = 26.0 Δ𝐻 = 26.0
145ᵒ 2.0 kW 145ᵒ 116.0 kW

Δ𝐻 = 1.0 Δ𝐻 = 1.0
135ᵒ 1.0 kW 135ᵒ 115.0 kW

Δ𝐻 = 75.0 Δ𝐻 = 75.0
85ᵒ –74.0 kW 85ᵒ 40.0 kW

Δ𝐻 = 40.0 Δ𝐻 = 40.0
75ᵒ –114.0 kW 75ᵒ 0 kW

It’s a threshold problem!

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STEP 2: Calculation of Utility CP
The temperature of the hot utility (MP steam) is assumed to change
from 190°C to 189°C (condensing medium pressure steam)

𝑄𝐻,𝑚𝑖𝑛 114 kW kW
𝐶𝑃𝐻𝑈 = = = 114
Δ𝑇 1°C °C

Note that this is an approximation to avoid using infinite values of CP

for condensing steam!

20
STEP 3: Balanced Hot Composite Curve (BHCC)
Temperature Stream Δ𝑇𝐼𝑁𝑇𝐸𝑅𝑉𝐴𝐿 σ 𝐶𝑃𝐻 Δ𝐻𝐼𝑁𝑇𝐸𝑅𝑉𝐴𝐿 Δ𝐻𝐶𝑈𝑀
boundary Population (ᵒC) (kW/ᵒC) (kW) (kW)

90ᵒ 0.0
CP = 2.5
50 –2.5 –125.0
140ᵒ 125.0
CP = 1.4

10 –3.9 –39.0
150ᵒ 164.0
2 30 –1.4 –42.0
180ᵒ 206.0
1 9 0 0
189ᵒ 206.0
CP = 114

1 –114.0 –114.0
190ᵒ 320.0
H

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STEP 4: Balanced Cold Composite Curve (BCCC)

Temperature Stream Δ𝑇𝐼𝑁𝑇𝐸𝑅𝑉𝐴𝐿 σ 𝐶𝑃𝐶 Δ𝐻𝐼𝑁𝑇𝐸𝑅𝑉𝐴𝐿 Δ𝐻𝐶𝑈𝑀

boundary Population (ᵒC) (kW/ᵒC) (kW) (kW)

3
70ᵒ 0.0
CP = 4
80 4.0 320.0
150ᵒ 320.0

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STEP 5: Balanced Composite Curves

Since the BCCC consists of one segment the enthalpy intervals are defined by the
points at which the BHCC changes slope 23
STEP 6: Calculation of Temperatures on
the BCCC

Enthalpy Δ𝐻𝐶𝑈𝑀 CP /
𝑇𝐻 (ᵒC) 𝑇𝐶 (ᵒC)
interval (kW) (kW/°C)

0 90 70
1 2.5
125 140 𝑇𝑐2
2 3.9
164 150 𝑇𝑐3
3 1.4
206 180 𝑇𝑐4

206 189 𝑇𝑐5

4 114.0
320 190 150

unknown

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 STEP 6: Calculation of Temperatures on
the BCCC

Enthalpy Δ𝐻𝐶𝑈𝑀 CP /
𝑇𝐻 (ᵒC) 𝑇𝐶 (ᵒC)
interval (kW) (kW/°C)

0 90 70
1 2.5 125 kW
𝑇𝑐2 = 70°C + = 101.25°C
125 140 𝑇𝑐2 4 kW/°C
2 3.9
164 150 𝑇𝑐3 164 kW
3 1.4 𝑇𝑐3 = 70°C + = 111.0°C
206 180 𝑇𝑐4 4 kW/°C

206 189 𝑇𝑐5 206 kW

𝑇𝑐4 = 70°C + = 121.5°C
4 114.0 4 kW/°C
320 190 150
206 kW
𝑇𝑐5 = 70°C + = 121.5°C
4 kW/°C

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 STEP 7: Calculation of Δ𝑇𝐿𝑀 for each
Interval

Enthalpy Δ𝐻𝐶𝑈𝑀 BHCC BCCC 90 − 70 − (140 − 101.25)

interval (kW) Temp. Temp. Δ𝑇𝐿𝑀1 =
90 − 70
= 28.35°C
ln
140 − 101.25
0 90 70
1 140 − 101.25 − 150 − 111
125 140 101.25 Δ𝑇𝐿𝑀2 = = 38.87°C
140 − 101.25
2 ln
150 − 111
164 150 111
3
206 180 121.5 Δ𝑇𝐿𝑀3 = 48.09°C

206 189 121.5 Δ𝑇𝐿𝑀4 = 62.89°C

4
320 190 150
Δ𝑇𝐿𝑀5 = 52.56°C

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 STEP 8: Calculation of A for each Interval

1 𝑞𝑖,𝑛 𝑞𝑗,𝑛
𝐴𝑛,𝑚𝑖𝑛 = 𝑛 ෍ + ෍
Δ𝑇𝐿𝑀 ℎ𝑖,𝑛 ℎ𝑗,𝑛
ℎ𝑜𝑡 𝑠𝑡𝑟𝑒𝑎𝑚𝑠 𝑖 𝑐𝑜𝑙𝑑 𝑠𝑡𝑟𝑒𝑎𝑚𝑠 𝑗

140°C − 90°C ∙ 2.5kW/°C

Enthalpy Δ𝐻𝐶𝑈𝑀 𝑇𝐻 𝑇𝐶 Δ𝑇𝐿𝑀 𝐴1 =
interval (kW) (ᵒC) (ᵒC) (ᵒC) 0.123 kW/m2 °C ∙ 28.35°C

0 90 70 (101.25°C − 70°C) ∙ 4kW/°C

1 28.35 + 2
= 71.70 m2
0.123 kW/m °C ∙ 28.35°C
125 140 101.25
2 38.87
164 150 111 𝐴2 = 16.31 m2
3 48.09
206 180 121.5
206 189 121.5 𝐴3 = 14.20 m2
4 52.56
320 190 150
𝐴4 = 33.27 m2

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Heat Exchanger Area Target
Enthalpy Δ𝐻𝐶𝑈𝑀 𝑇𝐻 (ᵒC) 𝑇𝐶 (ᵒC) Δ𝑇𝐿𝑀 (ᵒC) 𝐴 (m2 )
interval (kW)

0 90 70
1 28.35 71.70
125 140 101.25
2 38.87 16.31
164 150 111
3 48.09 14.20
206 180 121.5

206 189 121.5

4 52.56 35.27
320 190 150

Total area: 137.48 m2

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Summary
• The capital cost depends on the number and design of HE

• Target HE area is obtained using Balanced Composite Curves

• Presented heuristic method is applicable only to systems with

low variations of film transfer coefficient

29