PROCESS AND FOOD PLANT

DESIGN (EPF4802)
CHAPTER 5 (PART 2): UTILITIES &
ENERGY EFFICIENT DESIGN
By:
Assoc. Prof. Dr. Siti Hajar Othman
Department of Process and Food Engineering
Faculty of Engineering
s.hajar@upm.edu.my
Learning Outcomes
• Able to recognize different types of utilities
• Able to recognize different types of energy recovery
• Able to understand about optimum heat exchanger
network
• Able to conduct pinch analysis
Optimum Heat Exchanger Network

What is the idea of Heat Exchanger Network?

Cooler
𝑄𝑐ሶ = 180 kW
40C 100C 40C 100C
C H1 H1

20C 60C 60C

C1 H C1 20C
Heater Heat exchanger
𝑄𝐻ሶ = 180 kW 𝑄ሶ = 180 kW

Before energy integration After energy integration

Through two streams from any process Transferring Heat Load

from Source (hot stream 1) to Sink (cold stream 2)
Replacement both Cooler (C) and Heater (H) by a Heat
Exchanger
 Optimum Heat Exchanger Network

o Heat exchanger network (HEN); important technique for maximizing heat recovery in
the industrial processes and reducing external heating and cooling utilities
o Pinch analysis (PA); one of the most methods used to design HEN and integrate heat
o PA; in utilities integration and energy recovery realized by transforming the process
streams into the composite curves (CC)
o CC; will be used to estimate the minimum external requirements of hot and cold
utilities, which are the non-overlapping segments of the cold and hot CC.
o Maximum heat recovery represents in CC by the overlap region between hot and cold
CC
o CC play an important role in the process design; for the designing a HEN directly

Principle of PA
T
𝐶𝑃 = 𝑚𝐶
ሶ 𝑝
Δ𝐻 = 𝑄ሶ = 𝑚𝐶
ሶ 𝑝 Δ𝑇 T
𝐶𝑃 = Δ𝐻/Δ𝑇 Slope = 1/ CP
H
CP – heat capacity flowrate
Cp – specific heat capacity H
𝑚ሶ – mass flowrate Presentation of hot stream on T-H diagram
ΔH – change in enthalpy
Qሶ – heat flowrate
Δ𝑇 – change in temperature
 Optimum Heat Exchanger Network:
Case study

We applied Pinch technique

C
on a case study with a plant
flowsheet, where;
o The feed is heated to the 20C 160C
H
reaction temperature C1 C
H1
o The reactor effluent is Reactor feed 180C 20C
Overhead
further heated, and the
product
products are separated in
a distillation column
o The reboiler and
120C
condenser use external H
utilities C2 260C
Reactor effluent H Bottom
o The overhead and bottom product
products are cooled and 280C H2
C
sent for further processing 60C
Identification of hot, cold, utility streams in the process

International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-

2018
 Optimum Heat Exchanger Network:
Case study
Classification the process into streams with its thermal and physical properties is shown
in the Table. As a beginning for HEN design represent the streams in the form of grid
diagram as shown in the Figure where the actual consumption of external utilities is:
Heating load = 14000 KW, Cooling load = 13800 KW, Cost of hot utility = 140.2 $/KW.yr,
Cost of cold utility = 7.1 $/KW.yr

Extraction of thermal data for process streams and utilities

Hot pinch
Stream Stream Tin Tout CP 𝑄𝐶ሶ = 7200 kW
180C 20C
name (C) (C) (KW/C) H
C
1
C1 Reactor 20 160 40
𝑄𝐶ሶ = 6600 kW
feed 280C
H 60C
2 C
C2 Reactor 120 260 60
effluent ሶ
160C 𝑄𝐻 = 5600 kW 20CC
H1 Overhead 180 20 45 H 1

product ሶ
260C 𝑄𝐻 = 8400 kW 120C
C
H2 Bottom 280 60 30 H 2
product
Cold pinch
Grid for four-stream problem
Optimum Heat Exchanger Network:
Case study 180C
Hot pinch
𝑄𝐶ሶ = 7200 kW
H 20C
1 C

𝑄𝐶ሶ = 6600 kW
280C 60C
H
2 C

ሶ
160C 𝑄𝐻 = 5600 kW 20CC
H 1

ሶ
260C 𝑄𝐻 = 8400 kW 120C
H2 H C
C2 2

Cold pinch

H1
C1
 Optimum Heat Exchanger Network: H2 C2

Case study C1
H1

C2
H2

C1
H1

Rearrange (move horizontally) the streams based on actual heating load and cooling load
The arrangement will be further used for composite curve development
Optimum Heat Exchanger Network:
Case study

Slope = 1/ CP

Cold and hot stream composite curves

 Optimum Heat Exchanger Network:
Case study

300

250

200
T (C)

150

100
13800 kW
50
14000 kW
0
0 5000 10000 15000 20000
Enthalphy (kW)

Estimation of minimum utilities by composite curves: Move horizontally the cold/hot

stream composite curve (hot stream must be above cold stream); to obtain ΔTmin =
10⁰C
 Optimum Heat Exchanger Network:
Case study

∆𝑇𝑚𝑖𝑛
Cold stream 𝑇𝑖𝑛𝑡 = 𝑇 + 2
Tint (⁰C)
∆𝑇𝑚𝑖𝑛 CP 30
Hot stream 𝑇𝑖𝑛𝑡 = 𝑇 − H
280⁰C
2 275 2
1
260⁰C
Stream Actual Interval 265
CP 45
2 H
temperature temperature 175 1 180⁰C
(⁰C) (⁰C) 3
160⁰C
165
1 (cold) 20 160 25 165 4
125
5 C2 120⁰C
2 (cold) 120 260 125 265 CP 60
55
6 60⁰C
3 (hot) 180 20 175 15 25 C
7 20⁰C
1
CP 40
15
4 (hot) 280 60 275 55 20⁰C

Interval temperature for ΔTmin = Representation of streams on boundary intervals

10⁰C (120 - 130⁰C)
 Optimum Heat Exchanger Network:
Case study

∆𝐻 = ෍ 𝐶𝑃𝐶 − ෍ 𝐶𝑃𝐻 ∆𝑇

Definition and calculation of enthalpy change for every interval

Interval Interval Interval ΔT (⁰C) ΔH (kW) Surplus /
temperature (⁰C) Deficit

275
1 265
10 (– 30)*10 = -300 s
2 175
90 (60 – 30)*90 = 2700 d
3 165 10 (60 – 45 – 30)*10 = -150 s
4 125 40 (40 + 60 – 45 - 30)*40 = 1000 d
5 55 70 (40 – 45 – 30)*70 = -2450 s
6 25 30 (40 – 45)*30 = -150 s
7 15 10 (0 – 45)*10 = -450 s
 Optimum Heat Exchanger Network:
Case study

275⁰C 0 kW 275⁰C 3250 kW 𝑄ሶ 𝐻

-300 kW -300 kW
265⁰C 300 kW 265⁰C 3550 kW
2700 kW 2700 kW
175⁰C -2400 kW 175⁰C 850 kW
-150 kW -150 kW
165⁰C -2250 kW 165⁰C 1000kW

Boundary
1000 kW 1000 kW 𝑄ሶ 𝐶
pinch point 125⁰C -3250 kW 125⁰C 0 kW
(120 - 130⁰C) -2450 kW -2450 kW
55⁰C -800 kW 55⁰C 2450 kW
-150 kW -150 kW Grand composite curve
25⁰C -650 kW 25⁰C 2600 kW
-450 kW -450 kW
15⁰C -200 kW 15⁰C 3050 kW

Estimation of minimum utilities by problem table algorithm through heat cascade principle
Optimum Heat Exchanger Network:
Case study

130⁰C

CP 180C 2250 kW 4000 kW 950 kW

H 20C
45 41.1C
1
Above pinch Below pinch

280C 1600 kW 2100 kW

2900 kW 60C
30 H 183.3C
Above pinch : CPH ≤ CPC
2
Below pinch : CPH ≥ CPC
160C 20C
C
40
1

260C 120C
60 157.5C C
2
205.8C
𝑄𝐻ሶ = 3250 kW 𝑄𝐶ሶ = 3050 kW
Number of unit: 7
120⁰C (two coolers)

Proposed HEN design for ΔTmin = 10⁰C

Optimum Heat Exchanger Network:
Case study

130⁰C

CP 180C 2250 kW 1900 kW 3050 kW

H 87.8C
20C
45 1
Above pinch Below pinch

280C 2900 kW 1600 kW 2100 kW

H 60C Above pinch : CPH ≤ CPC
30 183.3C
2
Below pinch : CPH ≥ CPC
160C 20C
C
40 1 Stream was split to
CP = 19
obtain CPH ≥ CPC
CP = 21 for below pinch
260C 120C
60 157.5C C
2
205.8C

𝑄𝐻ሶ = 3250 kW 𝑄𝐶ሶ = 3050 kW

Number of unit: 7
120⁰C

Alternative of HEN design for ΔTmin = 10⁰C

Optimum Heat Exchanger Network:
Case study

130⁰C

CP 180C 2250 kW 1900 kW 3050 kW

H 87.8C
20C
45 1

280C 2900 kW 1600 kW 2100 kW

H 60C
30 183.3C
2

160C 20C
C
40 1

260C 120C
60 157.5C C
2
205.8C

𝑄𝐻ሶ = 3250 kW 𝑄𝐶ሶ = 3050 kW

120⁰C

Loop in HEN
Optimum Heat Exchanger Network:
Case study

CP 180C 2250 kW 1900 kW 3050 kW

H 87.8C
20C
45 1

280C 2900 kW 3700 kW

H 60C
30 183.3C
2

160C 20C
C
40 1
CP = 13.6
CP = 26.4 120C
260C
60 157.5C C
2
205.8C

𝑄𝐻ሶ = 3250 kW 𝑄𝐶ሶ = 3050 kW

Number of unit: 6

Alternative HEN design after loop breaking

 Optimum Heat Exchanger Network:
Case study

Before pinch analysis

Heating load: 14000 kW
Cooling load: 13800 kW
Cost of hot utility: 1,962,800 $/yr
Cost of cold utility: 97,980 $/yr
Total: 2,060,780 $/yr
 Optimum Heat Exchanger Network:
Case study

After pinch analysis

Heating load: 3250 kW
Cooling load: 3050 kW
Cost of hot utility: 455,650 $/yr
Cost of cold utility: 21,655 $/yr
Total: 477,305 $/yr
77% reduction!
 Recall
• Optimum heat exchanger network – idea, pinch
analysis