II

SIMPLE HEAT EXCHANGER NETWORK

Hot stream

Furnace

Cold stream
FEHE Reactor

Fuel Cooler

Coolant

Dr. Eng. Yulius Deddy Hermawan

Department of Chemical Engineering
UPN “Veteran” Yogyakarta
http://ydhermawan.wordpress.com/
 Outline
❑ Heat Recovery and Heat Exchange
▪ Basic concept of heat exchange
▪ T/H diagram
▪ Composite curves
▪ The problem table
❑ Heat Exchanger Network Design
▪ Network great representation
▪ A commonsense network diagram
▪ Design for MER
▪ Choosing Tmin: Supertargeting
❑ Energy Targeting
▪ Targeting heat exchange unit

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 II.1
HEAT RECOVERY AND HEAT EXCHANGE

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Case 2.1: simple process flowsheet
(Kemp, I. C., 2007)

❑ Reactor presents as a
black box.
❑ Any flow which
requires to be heated
or cooled, but does
not change in
composition, is
defined as a stream
❑ The feed, which
starts cold and needs
to be heated up, is Stream Mass Specific Heat Initial Final (target) Heat load
known as a cold flowrate heat capacity (supply) temperature H (kW)
stream. W (kg/s) capacity flowrate temperature T T (oC)
Cp CP T S (oC)
❑ Conversely, the hot
[kJ/(kgK)] [kW/K]
product which must
be cooled down is Cold 0.25 4.00 1.00 20 200 180
called a hot stream. Hot 0.40 4.50 1.80 150 50 -180

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

Simple process flowsheet with heat exchange for Case 2.1.
(Kemp, I. C., 2007)

Total Heat: Slope:

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Case 2.1.
Stream plotted on temperature/enthalpy (T/H) diagram with T=0 oC

210 Cooling duty Heat recovery Heating duty

200 50 kW 130 kW 50 kW
190
180
170
160
150
140
130
120
T (oC)

110
100
90
80
70
60
50
40
hot stream
30
cold stream
20
10
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
H (kW)
Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY
 Case 2.1.
Stream plotted on temperature/enthalpy (T/H) diagram with T=20 oC

210 Cooling duty Heat recovery Heating duty

200 70 kW 110 kW 70 kW
190
180
170
160
150
140
130 Temperature difference
120 Tmin = 20 oC
T (oC)

110
100
90
80
70
60
50
40
hot stream
30
cold stream
20
10
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
H (kW)
Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY
 COMPOSITE CURVE

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Case 2.2: four streams
(Kemp, I. C., 2007)

No Type CP Actual Temperature  H ShiftedTemperature

[kW/K] o o [kW] o o
T S [ C] T T [ C] S S [ C] S T [ C]
1 Cold 2 20 135 230 25 140
2 Hot 3 170 60 -330 165 55
3 Cold 4 80 140 240 85 145
4 Hot 1.5 150 30 -180 145 25

By using composite curve, find:

a. Heating Utility Duty
b. Cooling Utility Duty
c. MER (Maximum Energy Recovery)
use Tmin = 10 oC

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Composite Curve of cold stream for Case 2.2.
HC = 230+240 = 470 kW

180 240 kW
170
160 230 kW
150
140
130
4(140-135) = 20 kW
120
110
100
(4+2)(135-80) = 330 kW
90
T (oC)

80
70
60
50
40 2(80-20) = 120 kW
30
20
10
0
0 50 100 150 200 250 300 350 400 450 500 550 600

H (kW)

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Composite Curve of cold stream for Case 2.2.
HC = 230+240 = 470 kW

180 120 kW 330 kW 20 kW

170
160
150
140
130
4(140-135) = 20 kW
120
110
100
(4+2)(135-80) = 330 kW
90
T (oC)

80
70
60
50
40 2(80-20) = 120 kW
30
20
10
0
0 50 100 150 200 250 300 350 400 450 500 550 600

H (kW)

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Composite Curve of hot stream for Case 2.2.
HH = 180+330 = 510 kW
330 kW
180
180 kW
170
160
3(170-150) = 60 kW
150
140
130
120
110
100
(3+1.5)(150-60) = 405 kW
90
T (oC)

80
70
60
50
40 1.5(60-30) = 45 kW
30
20
10
0
0 50 100 150 200 250 300 350 400 450 500 550 600

H (kW)

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Composite Curve of hot stream for Case 2.2.
HH = 180+330 = 510 kW
45 kW 60 kW
180 405 kW
170
160
3(170-150) = 60 kW
150
140
130
120
110
100
(3+1.5)(150-60) = 405 kW
90
T (oC)

80
70
60
50
40 1.5(60-30) = 45 kW
30
20
10
0
0 50 100 150 200 250 300 350 400 450 500 550 600

H (kW)

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Composite Curve of hot stream for Case 2.2.
Cooling duty Heat recovery Heating duty
180 60 kW 450 kW 20 kW
170
160
150
140
130
120
110
100
90
T (oC)

80
70
Pinch
60
50
40
30
20
10
0
0 50 100 150 200 250 300 350 400 450 500 550 600

H (kW)

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 ASG. 2.1
No Type CP Actual Temperature H
[MW/K] T [oC] T [oC] [MW]
S T
1 Cold 0.20 20 180 32.0
2 Hot 0.15 250 40 -31.5
3 Cold 0.30 140 230 27.0
4 Hot 0.25 200 80 -30.0
By using Table of Exercise 2.1, and use Tmin = 10 oC
a. Develop composite curve
b. Determine Heating Utility Duty
c. Determine Cooling Utility Duty
d. Determine MER (Maximum Energy Recovery)

DEADLINE:
Simpan File Excel dengan nama: NIM_NAME_ASG2-1_PJPP

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 THE PROBLEM TABLE

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

The Problem Table
(Kemp, I. C., 2007)
No Type CP Actual Temperature  H ShiftedTemperature

Enthalpy balances [kW/K]

T S [oC] T T [oC]
[kW]
S S [oC] S T [oC]
1 Cold 2 20 135 230 25 140
2 Hot 3 170 60 -330 165 55
3 Cold 4 80 140 240 85 145
4 Hot 1.5 150 30 -180 145 25
Si = Shifted temperature interval number i
Si+1 = Shifted temperature interval number i+1

COLD:

HOT:

Consider Case 2.2,

Streams and
temperature intervals
Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY
 The Problem Table:
Temperature interval and heat load for Case 2.2.

(Kemp, I. C., 2007)

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Infeasible and feasible heat cascades for Case 2.2.

Pinch

(Kemp, I. C., 2007)

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY
 GCC for Case 2.2.

(Kemp, I. C., 2007)

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY
 II.2
HEAT EXCHANGER NETWORK DESIGN

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 SIMPLE GRID DIAGRAM

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Initial grid diagram for Case 2.2.

(Kemp, I. C., 2007)

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 “Commonsense network design for Case 2.2.

❑ What have we done wrong?

❑ Has MER been achieved?
(Kemp, I. C., 2007)
Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY
 Design for Maximum Energy Recovery
(Linnhoff and Hindmarsh, 1983)

❑ To achieve the maximum energy recovery (MER):

1. Don’t transfer heat across the Pinch
2. Don’t use cold utilities above
3. Don’t use hot utilities below

❑ Design is produced by:

1. Dividing the problem at the pinch, and designing each part
separately
2. Starting the design at the pinch and moving away
3. Immediately adjacent to the pinch, obeying the constraints:
CPHOT ≤ CPCOLD (above)
CPHOT ≥ CPCOLD (below)
4. Maximising exchanger load
5. Supplying external heating only above the pinch, and external
cooling only below the pinch

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

Consequences of matching streams of different CPs for Case 2.2.
HEN design of above the pinch

(a)

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

Consequences of matching streams of different CPs Case 2.2.
HEN design of above the pinch

(b)

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Above-pinch network design for Case 2.2.

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

Below-pinch
network
design for
Case 2.2.

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

Network Design Achieving Energy Target for Case 2.2.

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 HEN Case 2.2
1

COOLER HE-04

2
HE-01 HE-03

4
HE-02

HEATER
Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY
 ASG 2.2
No Type CP Actual Temperature H
[MW/K] T [oC] T [oC] [MW]
S T
1 Cold 0.20 20 180 32.0
2 Hot 0.15 250 40 -31.5
3 Cold 0.30 140 230 27.0
4 Hot 0.25 200 80 -30.0
1. By using the problem table, calculate:
a. Heating Utility Duty (Uheating)
b. Cooling Utility Duty (Ucooling)
c. MER (Maximum Energy Recovery)
d. Develop The Grid Diagram (HEN) to achieve energy target!
use Tmin = 10 oC

2. Develop GCC!
DEADLINE:
Simpan File Excel dengan nama: NIM_NAME_ASG2-2_PJPP.xlsx
Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY
 II.3
ENERGY TARGETING

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Choosing Tmin: Supertargeting

❑ Higher value of Tmin give higher hot and cold utility

❑ We want a Tmin as low as possible to give MER
❑ But, lower Tmin values give larger and more costly heat
exchangers.
❑ In a heat transfer device, the surface area
A required for heat exchange is given by
A : surface are in m2.
Q : the heat transferred in the exchanger (kW)
U : the overall heat transfer coefficient [kW/(m2K)]
TLM : the log mean temperature difference [K]

❑ For countercurrent HE: Tc1

and Th2 are at the “cold
end” C, and Th1 and Tc2 are
at the “hot end” H of HE
Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY
Utility use, exchanger area and cost variation with Tmin .
(Kemp, I. C., 2007)

• <<Tmin : very
large and costly HE,
and even if >>Tmin
• Utility use rises
linearly with Tmin
• Exc. Area rises very
sharply
(asymptotically) for
low Tmin.

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Threshold Problem: consider again Case 2.2.
Cooling duty Heat recovery Heating duty
180 40 kW 470 kW 0 kW
170
160
150
140
130
120
110
100
90
T (oC)

80
70
Pinch there is a near-pinch at 85°C for hot streams,
60
Tthreshold = 5 oC 80°C for cold streams
50
40
30
20
10
0
0 50 100 150 200 250 300 350 400 450 500 550 600

H (kW)

• the value of ΔTmin at which one utility target falls to zero is termed “ΔTthreshold”,
• a situation where only one utility is required is called a threshold problem.
Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY
 Targeting Heat Exchange Units
(Kemp, I. C., 2007)

Consider again:
❑ The bare flow diagram
consists four streams
(1 hot, 3 colds)
❑ The target energy
performance for this
system as calculated by
the Problem Table
method shows that
only heating is
required, and no
cooling.
❑ Straight away then, we
know that the cooler is
surplus to requirement.

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Schematic of heat exchange units for specialty chemicals process

▪ This illustrates the

minimum number of
units design, i.e. 1
hot utility, 3 HE
▪ The total system is in
enthalpy balance:
Hhot + HU = Hcold
▪ Match cold streams 2
and 3 with hot
stream (total 1,045
units), gives the
residual 1165 units.
▪ Match the residual
load of hot stream
with cold stream 1,
thus need hot utility
(1068) supplied by
steam.
umin = minimum number of units (including heaters and coolers)
N = total number of streams (including utilities)
Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY (Kemp, I. C., 2007)
 Design with targets for specialty chemicals process

umin = 4 units:
• 3 HEs
• 1 Hutility
N = 5 streams
• 3 colds, 1 hot
• 1 hot utility

(Kemp, I. C., 2007)

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Principles of subsets and loops

The new unit being The total units

the match between (3 – 1) + (3 – 1) = 4
ST and C2

The extra unit

introduces a loop
into system:
ST-C1-H1-C2-ST (Kemp, I. C., 2007)

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Targeting for the minimum number of units
(Kemp, I. C., 2007)
• Fig (a) shows how the (a) Units targeting with subdivision at the pinch
targeting equation is
applied to a “maximum
energy recovery” (MER)
design.
• The pinch divides the
problem into two
thermodynamically
independent regions.
• Since the regions are
independent, the targeting
formula must be applied to
each separately as shown
(Linnhoff and Hindmarsh
1983).
• The total for the whole problem, “umin, MER”, is then the sum of the umins for
each region: Umin , MER = Umin , above pinch + Umin , below pinch
Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY
 Targeting for the minimum number of units
(Kemp, I. C., 2007)
• Suppose, however, that  (b) Units targeting without subdivision at
units of heat are transferred the pinch
across the pinch as shown in
Figure (b), thus increasing the
hot and cold utilities by .
• Now, the regions are no
longer thermodynamically
independent, and we have a
single problem.
• Re-applying the targeting
formula, that is ignoring the
pinch, leads to the conclusion
that: umin ≤ umin MER

• This is because in targeting for the MER design, streams that cross the
pinch are counted twice. The conclusion is that there is a trade-off
between energy recovery and number of units employed.

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Targeting for the minimum number of units
(Kemp, I. C., 2007)

Consider again this grid diagram with pinch = 85 oC.

We obtain: umin MER = (5 – 1) + (4 – 1) = 7

5 streams at above pinch: cold (1), cold (3), hot (2), hot (4), and heater-utility
4 streams at below pinch: cold (1), hot (2), hot (4), and cooler-utility

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

Final design (considering the pinch) gives only 6 units

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

• There is a co-incidence: above
the pinch, streams 2 and 3
form a subset, allowing the
hot end to be designed with
three units rather than four
(s=2 in Euler’s equation).

u=N+L–s=5+0–2=3

• conversely, applying the targeting formula to the whole problem ignoring the
pinch gives

umin = (6 – 1) = 5
(4 streams + 2 utilities)
(Kemp, I. C., 2007)
Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY
Hence by transferring energy across the pinch → reducing the number
of units is 1 as can be seen in the “commonsense” network design bellows:

which uses 5 units: two exchangers, two heaters and one cooler.

Similar techniques to reduce the number of heat exchanger is network relaxation,

and would be discussed next.

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Case 2.3.a
Stream data for three streams problem
CP Actual Temperature  H
Code Type [kW/K]
T [oC] T [oC] [kW]
S T
C1 Cold 3 50 140 270
H1 Hot 2 150 90 -120
H2 Hot 4 90 40 -200

By using Tmin = 10 oC, Calculate/develop:

a. Composite Curves
b. Problem Table
c. Grand Composite Curves
d. Pinch temperature
e. Heating utility duty
f. Cooling utility duty
g. MER (Maximum Energy Recovery)
h. Grid diagram (HEN) to achieve energy target

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Case 2.3.b

By using Tmin = 10 oC, Stream data for three streams problem

Calculate/develop:
Heat
a. Composite Curves Supply Target capacity
Heat
b. Problem Table Stream Type temp. temp. Duty flowrate
c. Grand Composite Curves T S (oC) T T (oC) H (MW) CP
d. Pinch temperature (MW.K-1)
e. Heating utility duty 1 Hot 150 30 3.0 0.025
f. Cooling utility duty 2 Hot 130 70 1.2 0.020
3 Cold 40 130 4.5 0.050
g. MER (Maximum Energy
Recovery)
Use your own calculator and/or
h. Grid diagram (HEN) to achieve spreadsheet in excel
energy target

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 Case 2.4

Stream data for five streams problem By using Tmin = 10 oC,

Calculate/develop:
No Type CP Actual Temperature  H a. Composite Curves
[kW/K] T S [oC] T T [oC] [kW] b. Problem Table
1 Hot 3 200 50 -450 c. Grand Composite Curves
2 Hot 1.5 240 100 -210
d. Pinch temperature
3 Hot 300 120 119 -300
4 Cold 4 30 200 680
e. Heating utility duty
5 Cold 2 50 250 400 f. Cooling utility duty
g. MER (Maximum Energy
Use your own calculator and/or Recovery)
spreadsheet in excel h. Grid diagram (HEN) to achieve
energy target

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY

 GOODLUCK

Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY