Notes on Stream Splitting

In order to demonstrate the purpose of stream splitting, the following problem is set up. There
are two hot streams and one cold stream present, with a ΔTmin = 20°C. However the thermal
capacities (CP) of both hot streams are lower than that of the cold stream.
120°C 80°C
1 CP=40 kW/K 1600 kW
120°C 60°C
2 CP=50 kW/K 3000 kW ΔTmin = 20°C
100°C 30°C
3 CP=40 kW/K 4200 kW
By performing a Pinch Analysis on the system, the following heat exchanger network (HEN)
is developed:
120°C 80°C 80°C
1 CP=40 kW/K 1 1600 kW
120°C 68°C 60°C
2 CP=50 kW/K 2 C 3000 kW
100°C 73.3°C 400 kW 30°C
3 CP=40 kW/K 1 2 4200 kW
1600 kW 2600 kW

However, if we perform an energy balance over

HEX 1, we determine the inlet temperature of
stream 3 is 73.3°C. This gives a temperature
difference of 13.3°C on the right hand side of the
heat exchanger.

By looking at the temperature-enthalpy (T-H)

diagram (Fig. 1), we notice that as we move left
from the ΔTmin, the temperature difference
decreases. This means that ΔT becomes smaller than
Fig. 1 - Temperature-Enthalpy Diagram for Example Problem
ΔTmin. But we set ΔTmin = 20°C as a constraint.
Therefore ΔT may not be less than 20°C anywhere. slope = rise/run
therefore, slope = ΔT/ΔH
Remember that the slopes of the stream lines on the T-H graph are but, ΔH = CP ΔT
inversely related to the Cp and mass flow of the stream. The ΔT/ΔH = 1/CP
problem is not with the temperatures, but with the slopes. That is, where, CP = m & Cp
the cold stream slope is too small – it needs to be greater so that ΔT therefore,
increases (Figure 2). slope = ΔT/ΔH = 1/ m & Cp
Fig. 2 - The relationship between CP,
m& and the slope of the stream lines on
The Cp is defined for a the T-H graph
particular material, and
cannot be changed. However, we are able to change
the mass flow rate ( m& ). In this example, we can
simply halve the flow rate by splitting the stream in
half. This will increase the slope of stream 1 but will
produce two streams instead of one.

Let’s go one step further. As prudent engineers, we

Fig. 3 - New T-H Diagram for Example Problem realise that one of these split streams could be
manipulated to have a heating requirement that matches one of the hot streams exactly. In this
example, we could make one of our split cold streams have a heating load of 1600kW. The
new T-H graph (Fig. 3) and a possible HEN are shown for this example.