5week Process-Design Heat-Exchanger-Networks I

NETWORKS
HEAT EXCHANGER
Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

1
Aim is….
The design of a heat exchanger network for a simple process
with only one or two streams that need heating and cooling is

usually straightforward.
When there are multiple hot and cold streams, the design is
more complex, and there may be many possible heat exchange
networks.
2
Aim is….
The design engineer must determine the optimum extent of
heat recovery, while ensuring that the design is flexible to
changes in process conditions and can be started up and

operated easily and safely.
3
The word exchanger really applies to all types of equipment in which heat is
exchanged but is often used specifically to denote equipment in which heat is
exchanged between two process streams.
Exchangers in which a process fluid is heated or cooled by a plant service

stream are referred to as heaters and coolers.
If the process stream is vaporized, the exchanger is called a vaporizer if the

stream is essentially completely vaporized,
a reboiler if associated with a distillation column,
an evaporator if used to concentrate a solution.
The terms fired exchanger and fired heater are used for exchangers heated
by combustion gases, such as boilers;
other exchangers are referred to as unfired exchangers.
4
Heat - transfer Fluids
Water
Critical pressure and temperature values of water are 220 bar and 373.14° C.
Steam is a valuable heating agent below 200° C, where the saturation pressure
is about 24 bar. Superheated steam can be used to enlarge the temperature
range.
Liquid water is excellent for cooling, but also for heating at mild temperatures

below 100 ° C. For higher temperatures thermal fluids are more suitable.
Salt Brines
Salt brines are water solutions of inorganic salts. Aqueous CaCl2 solutions of
maximum 25% are recommended down to −20 ° C. Salt brines are low cost but
expensive in operation. Antifreezes described below are preferable.
Glycol Solutions
Ethylene glycol can be used in principle down to −35 °C, but in practice is
limited to −10 °C because of high viscosity. Propylene glycol has the advantage
of being nontoxic. Other antifreeze fluids, such as methanol and ethanol
solutions raise safety and toxicity problems.
5
Refrigerants
Refrigerants remove heat from a body or process fluid by vaporization.
Ammonia (R717) seems to be popular again after years of decline in favor of
chlorinated hydrocarbons (CFCs).
Because of damage to the ozone layer, the CFCs

are being replaced by refrigerants based on hydrochlorofluorocarbons (HCFC),
although these are not completely inoffensive.
Thermal Fluids
By using thermal fluids

the heat- transfer
operations can be carried
out over a larger
temperature interval but
at reasonable operating
pressures.
6
Inorganic Salts
Several formulations are known but the most widely used salt is a molten
mixture of the eutectic NaNO2 (40%)/NaNO3 (7%) /KNO3 (53%), for
operation between 146° C (melting point) and 454° C.

7
Heat - Exchangers
Shell - and - tubes Heat Exchangers
Heat-transfer area per unit volume is greatly increased by placing a large

number of small-diameter tubes inside a shell, that is, a pressure vessel.

Shell-and-tube heat exchanger - 1-1 fixed head
Segmental baffles
8
Heat - Exchangers
When employing a shell-and-tube heat exchanger, a decision must be made as to

which fluid passes through the tubes (tube side) and which passes through the
shell outside the tubes (shell side).

NOTE:
 The tube side is for corrosive, fouling, scaling, hazardous, high-
temperature, high-pressure, and more expensive fluids.
 The shell side is for more viscous, cleaner, lower-flow rate, evaporating,
and condensing fluids
9
Rules for fluid side selection are:

1. Corrosion: most corrosive fluid to the tube side
2. Fouling: fouling fluids in tubes.
3. Fluid temperatures: high- temperature fluid in tubes.

4. Pressure: high- pressure fluids in tubes.
5. Pressure drop: lower pressure drop can be obtained in one or two passes.
6. Condensing steam and vapor at low pressures: shell side.
7. Condensing gas– liquid mixtures: tube side with vertical position.
8. Stainless and special steels: corresponding fluid in tubes.
10
Shell-and-tube heat exchanger - 1-2 fixed head

Shell-and-tube heat exchanger - 1-2 floating head
11
Shell-and-tube heat exchanger - 1-2 U-tube

Shell-and-tube heat exchanger - 2-4 floating head
12
Overall heat - transfer coefficients for shell - and - tubes heat exchangers.

13
Overall heat - transfer coefficients for shell - and - tubes heat exchangers.

14
Overall heat - transfer coefficients for air - cooled heat (bare tube basis).

15
Overall heat - transfer coefficients for jacketed vessels.

16
Overall heat - transfer coefficients for immersed coils in agitated vessels.

17
Air - cooled Heat Exchangers
When cooling water is scarce, air is used for cooling and condensing liquid
streams in fin-fan heat exchangers.

18
Compact Heat Exchangers
When the two fluids

exchanging heat must be kept

clean, plate-and-frame heat
exchangers made of stainless
steel are commonly used.
19
Plate Heat Exchangers
Gasketed Plate Heat Exchangers
Selection:
The advantages and disadvantages of plate heat exchangers, compared with
conventional shell and tube exchangers, are as follows:
Advantages

1. Plates are attractive when material costs are high.
2. Plate heat exchangers are easier to maintain.
3. Low approach temps can be used, as low as 1oC,
compared with 5 to 10oC for
shell and tube exchangers.
4. Plate heat exchangers are more flexible; it is easy
to add extra plates.
5. Plate heat exchangers are more suitable for highly
viscous materials.
6. The temperature correction factor, Ft, will
normally be higher with plate heat
exchangers, as the flow is closer to true counter-
current flow.
7. Fouling tends to be significantly less in plate heat
exchangers; 20
FIRED HEATERS (FURNACES AND BOILERS)
 Furnaces (also called fired heaters) are often used to heat, vaporize, and/or
react process streams at high temperatures and high flow rates.
 Heat duties of commercial units are in the range of 3 to 100 MW
(10,000,000 to 340,000,000 Btu/hr).

Typical applications of fired heaters are
1. Process feed-stream heaters, such as the feed heaters for refinery crude
columns (pipe stills), in which up to 60% of the feed may be vaporized;
2. Reboilers for columns, using relatively small-size direct-fired units;
3. Direct-fired reactors, for example, the pyrolysis of dichloroethane to form vinyl
chloride;
4. Reformers for hydrogen production, giving outlet temperatures of 800–900 o C;
5. Steam boilers.
21
22
(HEND)
NETWORK DESIGN
HEAT EXCHANGER

23
Pinch Technology
The development and application of the method can be
illustrated by considering the problem of recovering heat
between four process streams:
two hot streams that require cooling and two cold streams

that must be heated.
Each stream starts from a source temperature: Ts
Each stream is to be heated or cooled to a target temperature: Tt
The heat capacity flow rate of each stream is : CP

For streams where the specific heat capacity can be taken as constant, and there is no
phase change :
m = mass flow rate, kg/s;
Cp = average specific heat capacity between Ts and
Tt kJ/ kg C 24
Some heat is exchanged between the streams in the heat exchanger.
Additional heat, to raise the cold stream to the target temperature, is

provided by the hot utility (usually steam) in the heater.
Additional cooling to bring the hot stream to its target temperature, by

the cold utility (usually cooling water) in the cooler.
25
Problem
Heat Capacity
Stream oC oC Heat Load,
Type Flow rate CP Ts Tt
Number kw
kW/oC
1 Hot 3.0 180 60 360

2 Hot 1.0 150 30 120
3 Cold 2.0 20 135 230
4 Cold 4.5 80 140 270
The task is to find the best arrangement of heat exchangers to

achieve the target temperatures.
26
To find the pinch temperatures and the
minimum utility requirements:

Two methods:
1. T-H diagrams
2. Problem Table Method
27
Temperature-enthalpy (T-H) diagram.
The stream temperatures are
plotted on the y-axis and the
enthalpy
change in each stream on
the x-axis.

∆Hhot : the heat transferred from the
hot utility
∆Hcold : the heat transferred to the
cold utility
For heat to be exchanged, a minimum temperature difference must be
maintained between the two streams = ∆Tmin

The practical minimum temperature difference will usually be between 5 and 30oC.
28
The heats can also be calculated as:

29
The same streams
plotted with a lower value
of ∆Tmin.
The amount of heat exchanged ↑↑

The utility requirements ↓↓
The temperature driving force for heat transfer ↓ ↓

So the heat exchanger has both a larger duty and a smaller
log-mean temperature difference. 30
This leads to an increase in the heat transfer area required and
in the capital cost of the exchanger.

The capital-energy trade-off in process heat recovery
31
The maximum feasible heat recovery is reached at the point
where the hot and cold curves touch each other on the T-H plot:
At this point, the temperature

driving force at one end of
the heat exchanger is zero

and an infinite heat
exchange surface is
required, so the design is not
practical.
The exchanger is said to be pinched at the end where the hot and cold
curves meet. The heat exchanger is pinched at the cold end.
It is not possible for the hot and cold streams to cross each
other, as this would be a violation of the second law of
thermodynamics. 32
This implies that in
any of the
exchangers to be
used in the network,
the temperature
difference between
the streams will not
be less than 10oC

In most exchanger
networks the
minimum
temperature
difference will
occur at only one
point. This is
termed the pinch.
The pinch occurs at between 90 o C on the hot stream curve and 80 o

C on the cold stream curve. 33
Pinch point
The pinch divides the system into two distinct thermodynamic
regions.
 The region above the pinch can be considered a heat sink, with
heat flowing into it, from the hot utility, but no heat flowing out of it.

 Below the pinch the converse is true. Heat flows out of the region
to the cold utility. No heat flows across the pinch.
34
2nd Way: Problem Table Method
1st Step: Convert the actual stream temperatures, Tact, into interval
temperatures, Tint, by subtracting half the minimum temperature
difference from the hot stream temperatures and by adding half to the
cold stream temperatures:

The use of the interval temperature rather than the actual temperatures
allows the minimum temperature difference to be taken into account.
∆ Tmin = 10oC for the problem being considered.
35
Problem Table Method
Heat Capacity
Stream Heat Load,
Type Flow rate CP TsoC TtoC
Number kw
kW/oC
1 Hot 3.0 180 60 360

2 Hot 1.0 150 30 120

3 Cold 2.0 20 135 230
4 Cold 4.5 80 140 270
1st step: Interval Temperatures for ∆ Tmin = 10oC
2ndStep: Note any duplicated interval temperatures. 36

3rd Step: Rank the interval temperatures in order of magnitude,
showing the duplicated temperatures only once in the order:

37
4th Step: Carry out a heat balance for the streams falling within
each temperature interval. For the nth interval:

38
5th Step: ‘Cascade’’ the heat surplus from one interval to the
next down the column of interval temperatures;

39
6th Step: Introduce just enough heat to the top of the cascade
to eliminate all the negative values

137.5 kW
40
Summary
For maximum heat recovery and minimum use of utilities:
1. Do not transfer heat across the pinch.
2. Do not use hot utilities below the pinch.

3. Do not use cold utilities above the pinch
41
Heat Exchanger Network Design
Grid Representation

Heat exchangers
42
Network Design for Maximum Energy
Recovery
Heat Capacity
Stream Heat Load,
Type Flow rate CP TsoC TtoC
Number kw
kW/oC
1 Hot 3.0 180 60 360

2 Hot 1.0 150 30 120
3 Cold 2.0 20 135 230
4 Cold 4.5 80 140 270
50 kW of the hot and 30 kW of the cold utility,

the pinch occurs where the cold streams are at 80oC and the hot
streams are at 90 o C.
43
Network Design for Maximum Energy
Recovery (minimum utility consumption)

Grid for four-stream problem
44
Network Design Above the Pinch
1. Stream 1 can be matched with stream 4, but not with 3

Matching streams 1 and 4 and transferring the full amount of heat required
to bring stream 1 to the pinch temperature gives
This will also satisfy the heat load required to bring stream 4 to its target
temperature:
45
2. Stream 2 can be matched with stream 3
Transferring the full amount to bring stream 2 to the pinch temperature:

3. The heat required to bring stream 3 to its target temperature, from the
pinch temperature, is
So, a heater will have to be included to provide the remaining heat load:
46
The proposed network design above the pinch is shown as:

47
Network Design Below the Pinch
1. Stream 4 begins at the pinch temperature, Ts = 80 oC, and so is not

available for any matches below the pinch.
2. A match between streams 1 and 3 adjacent to the pinch will satisfy the
heat capacity restriction but not one between streams 2 and 3.
So, 1 is matched with 3, transferring the full amount to bring stream 1 to its
target temperature:
3. Stream 3 requires more heat to bring it to the pinch temperature;

amount needed:
48
This can be provided from stream 2, as the match is now away from the
pinch.
The rise in temperature of stream 3 will be given by

So transferring 30 kW will raise the temperature from the source
temperature to:
and this gives a stream temperature difference on the outlet side of the
exchanger of
So, the minimum temperature difference condition, 10oC, will not be

violated by this match.
49
4. Stream 2 needs further cooling to bring it to its target temperature,
so a cooler must be included; cooling required:

This is the amount of the cold utility predicted by the problem
table.
50
Proposed Heat Exchanger Network
for ∆ Tmin = 10oC

Interior heat exchangers Auxiliary heat exchangers 51
Summary for HEND
The guide rules for devising a network for maximum heat recovery are
given below:
1. Divide the problem at the pinch.
2. Design away from the pinch.

3. Above the pinch match streams adjacent to the pinch, meeting the
restriction:
4. Below the pinch match streams adjacent to the pinch, meeting the
restriction:
5. If the stream matching criteria cannot be satisfied, split a stream.

6. Maximize the exchanger heat loads.
7. Supply external heating only above the pinch and external cooling only
below the pinch.
52
EXAMPLE: H.E.N.D.
Determine the pinch temperatures and the minimum utility requirements for the
streams set out in the following table, for a minimum temperature difference
between the streams of 20oC. Devise a heat exchanger network to achieve the
maximum energy recovery.

Heat Capacity
Stream Heat Load,
Type Flow rate CP Ts oC Tt oC
Number kW
kW/oC
1 Hot 40.0 180 40 5600

2 Hot 30.0 150 60 1800
3 Cold 60.0 30 180 9000
4 Cold 20.0 80 160 1600
53
SOLUTION
For ∆ Tmin = 20oC
Hot streams Tint = Tact - 10oC
Cold streams Tint =Tact + 10oC

Stream data
54
SOLUTION
Problem table

The final column gives a cascade showing only positive values, with zero energy
cascading at the pinch temperature.
The hot utility requirement is 2900 kW

The cold utility requirement, the bottom value in the column, is 600 kW.
55
SOLUTION
Problem table

So at the pinch;
hot streams will be at 90 + 10 = 100 oC
the cold streams will be at 90 - 10 = 80 oC
56
SOLUTION
Above Pinch
1. CPh ≤ CPc
2. Can match stream 1 or 2 with stream 3, but neither stream can match with

stream 4. This creates a problem, since if we match stream 1 with 3, then stream
2 will not be able to make a match at the pinch.
Likewise, if we match stream 2 with 3, then stream 1 will not be able to make a
match at the pinch.
3. Check the heat available in bringing the hot streams to the pinch temperature:
57
SOLUTION
4. Check the heat required to bring the cold streams from the pinch temperature to
their target temperatures:

5. If we split stream 3 into two branches with CP of 40.0 and 20.0, then we can
match the larger branch with stream 1 and transfer 3200 kW, which satisfies
(ticks off) stream 1.
6. We now have two cold streams, both with CP of 20.0 and one hot stream (2)
with CP of 30.0. We need to split stream 2 into two branches. As an initial guess,
these can both have CP of 15.0. We can then match one branch of stream 2 with
the smaller branch of 4 and transfer 750 kW, and the other branch with stream
3, also for 750 kW, which then ticks off stream 2.
58
SOLUTION
7. Include a heater on the smaller branch of stream 3 to provide the balance of
the heat required:

8. Include a heater on stream 4 to provide the balance of the heat required
Check sum of heater

duties =
2050 + 850 = 2900 kW = hot
utility target.
59
SOLUTION
Above Pinch

60
SOLUTION
Below Pinch
1. CPh ≥ CPc
2. Note that stream 4 starts at the pinch temperature so cannot provide any

cooling below the pinch.
3. Cannot match stream 1 or 2 with stream 3 at the pinch.
4. Split stream 3 to reduce CP
5. Check the heat available from bringing the hot streams from the pinch
temperature to their target temperatures:
61
SOLUTION
Below Pinch
6. Check the heat required to bring the cold streams from their source
temperatures to the pinch temperature:

stream 4 is at the pinch temperature.
7. Note that stream 1 cannot be brought to its target temperature of 40oC

by full interchange with stream 3, as the source temperature of stream 3
is 30 o C, so ∆Tmin would be violated. So transfer 1800 kW to one leg of
the split stream 3.
8. Check temperature at exit of this exchanger:
62
SOLUTION
Below Pinch
9. Provide cooler on stream 1 to bring it to its target temperature, cooling

needed:

10. Transfer the full heat load from stream 2 to second leg of stream 3; this
satisfies both streams.
63
SOLUTION
Proposed heat exchanger network

64
HOMEWORK-1: HEND
Determine the pinch temperature and the minimum utility requirements
for the process set out here. Take the minimum approach temperature
as 15oC. Devise a heat exchanger network to achieve maximum energy
recovery.
65
HOMEWORK-2: HEND
To produce a high purity product, two distillation columns are operated in
series. The overhead stream from the first column is the feed to the
second column. The overhead from the second column is the purified
product. Both columns are conventional distillation columns fitted with

reboilers and total condensers. The bottom products are passed to other
processing units, which do not form part of this problem. The feed to the
first column passes through a preheater. The condensate from the
second column is passed through a product cooler. The duty for each
stream is summarized as follows:
66
HOMEWORK-2: HEND - continued

Find the minimum utility requirements for this process, for a minimum
approach temperature of 10oC.
Note: The stream heat capacity is given by dividing the exchanger duty
by the temperature change.
67
HOMEWORK-3: HEND
Consider the design of a HEN for the four streams below in a problem:

68

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NETWORKS

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

The design of a heat exchanger network for a simple process

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

more complex, and there may be many possible heat exchange

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Exchangers in which a process fluid is heated or cooled by a plant service

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

If the process stream is vaporized, the exchanger is called a vaporizer if the

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Because of damage to the ozone layer, the CFCs

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

By using thermal fluids

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Heat-transfer area per unit volume is greatly increased by placing a large

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

When employing a shell-and-tube heat exchanger, a decision must be made as to

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Rules for fluid side selection are:

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

When the two fluids

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Each stream starts from a source temperature: Ts

Each stream is to be heated or cooled to a target temperature: Tt

The heat capacity flow rate of each stream is : CP

Additional heat, to raise the cold stream to the target temperature, is

Additional cooling to bring the hot stream to its target temperature, by

1 Hot 3.0 180 60 360

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

The task is to find the best arrangement of heat exchangers to

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

For heat to be exchanged, a minimum temperature difference must be

maintained between the two streams = ∆Tmin

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

The amount of heat exchanged ↑↑

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

The temperature driving force for heat transfer ↓ ↓

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

At this point, the temperature

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

The pinch occurs at between 90 o C on the hot stream curve and 80 o

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

1 Hot 3.0 180 60 360

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek

1st step: Interval Temperatures for ∆ Tmin = 10oC

2ndStep: Note any duplicated interval temperatures. 36

Process Design Lecture Notes / Assist.Prof.Dr. E.Bilgin Simsek