This course – Process Synthesis and Integration

Process Integration: Create Heat Exchanger Network and an Utility Network that serves
this process in an economical manner and environmental way.

1
Steps for a Heuristic Synthesis
1. Selection of the processing mode: continuous or batch

2. Selection of the reactional path and analysis of process inputs and

outputs
Distribute chemicals in a process flowsheet;

2
Steps for a Heuristic Synthesis

3. Optimization of the recycle structure of process

3
Steps for a Heuristic Synthesis
4. Apply heuristics/simulation tools in selecting separation processes to
heterogeneous mixtures (vapor-liquid mixtures) or homogeneous
(liquids, vapors, solids);

4
Steps for a Heuristic Synthesis
5. Adjust P, T and phase One single Hex or more than one?
Pre heat the mixture?

6. Energy Integration (HEN and Utilities)

5
 This course – Process Synthesis and Integration
Process Integration: Create Heat Exchanger Network and an Utility Network that serves
this process in an economical manner and environmental way.

6
How to improve Energy Efficiency at the Industrial sector ?

• Apply Process Integration methodologies

• Optimize the processes

• BATs

CFernandes 2021 7
 Energy Efficiency can have significant effects
Energy
Disposable Savings GHG
income emissions

Public Energy
budget Security

Resource Energy
management Energy delivery
efficiency
improvement

Local air Energy

pollution
prices

Strong energy efficiency policies Employment

Macro-
Economic
are vital to achieving the key Less poverty
Health impacts
and Industrial
energy-policy goals (IEA, 2017). CFernandes 2021 well- productivity 8
being
Process Integration
The definition used in this context is the one used by the IEA since 1993:

"Systematic and General Methods for Designing Integrated Production

Systems, ranging from Individual Processes to Total Sites, with special
emphasis on the Efficient Use of Energy and reducing Environmental Effects".

• Optimal Design and Operation of New and Existing Industrial Continuous and Batch Processes
• Industrial resources management. Optimization of external utilities
• Enhance the environmental efficiency through the recycle of sub products and effluents

Process Integration is a basic analysis tool that allows the process

engineer to design a more competitive industrial process
CFernandes 2021 9
GNIP – Grupo Nacional para a Integração de Prcessos

Members of GNIP in 2018

➢ IST ➢GALP/ PETROGAL
➢ DGEG ➢ Bondalti
➢ FEUP ➢ Instituto RAIZ
➢ ISEL ➢ ISEP Created in April 1995 !
CFernandes 2021 10
▪ As medidas políticas e tecnológicas para aumentar a EE devem seguir as
recomendações e directrizes gerais da UE (Portugal é um estado-membro) e
devem seguir os exemplos de sucesso implementados em alguns Países de
Referência! CFernandes 2021 11
 ENERGY EFFICIENCY

HEAT INTEGRATION

(1) Em relação ao balanço energético, juntaram-se os sectores do plástico e da borracha, e não foi considerado o sector outros
Fonte: Análise IST/ADENE CFernandes 2021 12
Hot and Cold streams / utilities

• A stream from a condenser at 40 ºC must enter a DC at 90 ºC.

Is this a cold stream?

If you answer YES, raise your hand!

CFernandes 2022 13
Hot and Cold streams / utilities

• A stream from a condenser at 40 ºC must enter a DC at 90 ºC.

To do so, what kind of utility do you need? A cold utility?

If you answer YES, raise your hand!

CFernandes 2022 14
PI - some basic concepts

Hot stream: Needs cooling por a

alor.
Cold stream: Needs heating d
– e calor.
External Utilities:
lCold utility: to cool hot streamspor d
Cooling water, air, brines

Hot utility: to heat cold streamspor a

Steam, thermofluids, flue gases

CFernandes 2022 15
Examples of Utilities

CFernandes 2022 16
CFernandes 2022 17
 Example 1 (initial scenario)
Cold Stream
210ºC HU 160ºC
Recirculation 160ºC
2500 kW
Compressor

130ºC

Cond.

Coluna de Destilação
Cold Stream
Reactor Feed 210ºC Reactor Effluent
HU CU
Reactor
50ºC 210ºC 270ºC 160ºC
3200 kW 1980 kW
Hot Stream Vaporiz.

220ºC CU
HEx: 4
220ºC 60ºC
Heat consumption : 11,2 MW 3520 kW Hot Stream
CFernandes 2022 Final Product 18
After Process Integration
190ºC 177,6ºC

160ºC
Compressor

235,6ºC 130ºC

Condensador

Coluna de Destilação
210ºC
180ºC 160ºC
Reactor
210ºC 270ºC

160ºC

Vaporizador
60ºC 80ºC 180ºC 220ºC
220ºC
Produto Final
50ºC

Alimentação
do Reactor

HEx: 7
Heat consumption : 1,8 MW CFernandes 2022 Total Cost reduction: 50% 19
 Pinch Analysis vs Mathematical methods

Pinch Analysis
A thermodynamic approach developed at
UMIST during 70´s by Prof. Bodo Linnhof
They need some initial points

CFernandes 2022 20
Energy Integration
6. Energy Integration (Pinch Analysis)

Importance of TARGETS
• Obtain an initial approximate solution
• Obtain the initialization of a mathematical solving method

21
Steps of Pinch Analysis
1) Data Extraction, which involves
collecting data from the process and
the utility system.

2) Targeting, which establishes figures

for best performance in various
respects.

3) Design, where an initial Heat

Exchanger Network is established.

4) Optimization, where the initial

design is simplified and improved
economically
CFernandes 2022 22
Some PI Software

• AspenTech Energy Analyser

(http://www.aspentech.com)

• AVEVA
(http://www.aveva.com/)

• UMIST
(http://www.cpi.umist.ac.uk)

• IST FIE2PI
CFernandes 2022 23
 Case Studies

T. Gundersen

CFernandes 2022 24
Limitations

Layout

Safety

Purity of final product

Operability

Control

Flexibility

CFernandes 2022 25
Process Integration : Pinch Analysis method

Pinch Analysis Increase the Efficient Use of Energy and

A thermodynamic approach developed at reduce Environmental Effects
UMIST during 70´s by Prof. Bodo Linnhof

First 2 steps:
1) Data Extraction, which involves
collecting data from the process
and the utility system.

2) Targeting, which establishes

figures for best performance in
various respects.
CFernandes 2022 26
Data collection

1. Design

2. Control room (registrations)

3. Local Measures

4. Heat and mass balances

i. Excel
ii. Simulators (Aspen Plus, Pro II, Hysys, gProms,
Speedup,…)

CFernandes 2022 27
Mass / Heat balance
Significant data reconciliation must take place, requiring consistency rather than precise accuracy.

For existing units: design data is often significantly different to actual performance: Flows will usually

be altered during commissioning to obtain stable behaviour, the raw material composition may have

altered, and heat exchangers become fouled and their performance drops. Hence, sometimes different

scenarios are needed for different feedstocks or before/after cleaning.

For a new plant: a heat and mass balance can be made from design data.

The mass balance needs to be based on mass flowrates. Few plants have flowmeters on all streams,

and they can show significant errors: flowmetres for steam (for example) are particularly prone to error

(30% or more are not uncommon).

It is always worthwhile to do a crosscheck data (ex: against annual production)

CFernandes 2022 28
 Flow meters
Venturi procedure Ultrasonic clamp-on flow meters for
A constriction in the flow path causes a gas and liquids | KTM
pressure drop across the meter. The Ultrasonic clamp-on flow meters for gas and

pressure drop can be measured and liquids are the portable devices for quick

correlated with flow rate. measurement of medium flow rate.

Ultrasonic liquid flow meters are used to
measure the volume of liquid media that do not
contain foreign inclusions.

Flow meters of this type are also called acoustic,

since they function in the ultrasonic frequency
Dipstick
Measure the level of a tank with a dipstick range.

CFernandes 2022 29
Heat balance
The heat balance is more complicated, we need:
temperatures, heat loads, heat losses, and the flowrates(from the mass balance)

Temperature is usually the most accurately measured parameter on a plant, often to

within 1°C/5ºC. However, sometimes we need to use a sampling point where a
thermocouple can be introduced or measure the external pipe temperature.

CFernandes 2022
https://www.researchgate.net/profile/Zoubair_Boulahia/post/Are_there_empirical_equations_to_estimate_the_internal_temperature_of_the_fluid_by_measuring_the_surface_temperature_of_the_pipe/attachment/59d6392079197b8077996572/AS%3A400518716379139%401472502511947/download/ExternaltemperaturemeasurementPent
ronicNews42013.pdf 30
Heat balance
Heat loads are more difficult. Specific heat capacities and latent heats of the process
streams can be obtained from literature/simulation, manufacturers’ data or (if necessary)
measurement.

To avoid this you may use in an existing plant:

Cooling loads obtained from the flowrate and temperature difference of the cooling water,
and
Heating loads from the steam flow (often inaccurate; condensate flow measurement may be
more adequate).
Identification of heating and cooling requirements in the process.
The necessary data for each process stream are the following:
HD = MCp stream x | Ts – Tt |

1) M = mass flowrate (kg/s, tons/h, etc.)

2) Cp = specific heat capacity (kJ/kg°C) Streams MCp (kW/ºC) Ts (ºC) Tt (ºC) HD (kW)

Mcp = M x cp (kJ/ºC, s)

3) Ts = supply temperature (°C); initial T

Tt = target temperature (°C); final T
4) Phase change enthalpy - ΔHvap = heat of vaporization for streams with a L-V phase
change (kJ/kg)
Identification of heating and cooling requirements in the process.
The necessary data for each process stream are the following:
HD = MCp stream x | Ts – Tt |

M = mass flowrate (kg/s, tons/h, etc.) 1 kg/s

Cp = specific heat capacity (kJ/kg°C)

Mcp (kJ/ºC,s) = M x cp = MCp

Ts = supply temperature (°C); initial T Streams MCp (kW/ºC) Ts (ºC) Tt (ºC) HD (kW)

Tt = target temperature (°C); final T

ΔHvap = heat of vaporization for streams with a L-V phase change (kJ/kg)

HD = 1 kg/s x 4,18 kJ/kg,ºC x (40-27)=54,34 kJ/s= 54,34 kW

MCp = 54,34 /(140 – 40) = 5,434 kW/ºC
Streams under phase change

When latent heat changes occur, the dew

and bubble points should be fixed as
linearisation points from the outset.

When MCp can not be considered constant,

streams should be linearised in sections.
 Slope is the inverse of MCP

HD = MCpHSt (TH,in – TH,out)

or

HD = MCpCSt (TC,out – TC,in)

CFernandes 2022 35
 Slope is the inverse of MCP

HEN – Heat Exchanger Network

DTmin approach
Minimum difference of temperatures that must be respected
between hot and cold streams
CFernandes 2022 36
 DTmin = 10ºC

Stream Tinitial, ºC Tfinal, ºC Mcp, HD, kW

kW/K
1 190 90 1 1 x (190 -90) = 100
2 80 140 2 2 x (140 -80) = 120
Draw the HEN – Heat Exchanger Network between this 2 streams when DTmin = 10ºC

CFernandes 2021 37
 HEN @ DTmin = 10ºC
MCp,kW/ºC
1

Draw the HEN – Heat Exchanger Network between this 2 streams when DTmin = 10ºC

CFernandes 2021 38
 HEN @ DTmin = 10ºC
MCp, kW/ºC HD, kW
1 1 x (180-100) = 100

2 2 x (140-80) = 120

DT= 190-140=50ºC

DT=
= 90 – 80 =10ºC

CFernandes 2021 39
 HEN @ DTmin = 20ºC
MCp,kW/ºC
1

Draw the HEN – Heat Exchanger Network between this 2 streams when DTmin = 20ºC

CFernandes 2021 40
DTmin = 20ºC

CFernandes 2022 41
 The influence of DTmin
DTmin = 10ºC

DTmin = 20ºC

DTmin, ºC Heat recovery, Hot Ut, kW Cold Ut, kW

kW
10 100 20 0
20 90 30 10
CFernandes 2022 42
Exercise PI.1
HD = 380 kW
Propose an
alternative for
Heat Integration
53ºC

78ºC

HD = 380 kW

CFernandes 2022 43
Exercise PI.2– calculate the missing T (DTmin=10ºC)

MCp, kW/ºC Ti, ºC Tf, ºC DH, kW

A 0.10 327 40 -28.7
B 0.16 220 160 -9.6
C 0.10 100 300 20
D 0.20 140 300 32

CFernandes 2021 44
Exercise PI.3 – Homework

CFernandes 2021 45
Process Integration : Pinch Analysis method

Pinch Analysis Increase the Efficient Use of Energy and

A thermodynamic approach developed at reduce Environmental Effects
UMIST during 70´s by Prof. Bodo Linnhof

First 2 steps:
1) Data Extraction, which involves
collecting data from the process
and the utility system.

2) Targeting, which establishes

figures for best performance in
various respects.
CFernandes 2022 46
 Targeting step

Minimum Consumption of Utilities

Graphical method Problem Table

Composite Curves Heat Cascade

CFernandes 2021 47
 Example 1
210ºC 160ºC
Recirculation 160ºC
2500 kW
Compressor

130ºC

Cond.

Coluna de Destilação
Reactor Feed 210ºC Reactor Effluent
Reactor
50ºC 210ºC 270ºC 160ºC
3200 kW 1980 kW
Vaporiz.

220ºC
220ºC 60ºC
3520 kW
CFernandes 2021 Final Product 48
 From data extraction
Ti Tf MCp HD h
(ºC) (ºC) (kW/ºC) =MCpDT (kW/m2/ºC)
(kW)
Streams
1 – Reactor Effluent 270 160 18 1980 0,5

2 – Final Product 220 60 22 3520 0,5

3 – Reactor Feed 50 210 20 3200 0,5

4 – Recirculation 160 210 50 2500 0,5

CFernandes 2021 49
 Composite curves
These curves are a representation of hot and cold streams in a
temperature/enthalpy diagram.

These curves are used to assess the energy needs of all process streams:
• Maximum amount of energy that can be recovered by heat transfer between
process streams;

• Minimum amount of heat to deliver to the process through hot utilities QUH;

• Minimum amount of heat to remove from the process through cold utilities: QUC

Its construction assumes that the value of MCp for each stream is constant
CFernandes 2021 50
 Construction of Composite Curves
▪ Representation of each stream on a
Temperature & Enthalpy diagram

▪ Division through temperature intervals

defined by inlet and outlet stream
temperatures

▪ For each interval the streams are

combined considering:

➢ MCp in each interval is equal to the

sum of the individual streams MCp
existing in that range;
or
➢ Calculating the total DH of the
streams existing in this range
CFernandes 2021 51
 Composite curves
270 MCp = 18 kW/ºC
240 Hot Composite Curve

Stream 1 Intervalo, i DHi, kW DHacum T, ºC

210
MCp = 18 kW/ºC
?
180 DH =1980 kW 5500 270
MCp = 40 kW/ºC III 18 x(270-220)=900
Stream 2
150
MCp = 22 kW/ºC 4600 220
T (ºC)

120
?
DH =3520 kW II (22 + 18) x(220-160)=2400
2200 160
90 I 22 x(160-60)=2200
0 60
60
MCp = 22 kW/ºC
30

0 1000 2000 3000 4000 5000 6000

DH (kW)

CFernandes 2021 52
Composite curves
270 MCp = 18 kW/ºC

240 Hot Composite Curve

Stream 1
210 MCp = 18 kW/ºC
?DH =1980 kW
180 MCp = 40 kW/ºC
Stream 2
T (ºC)
150 MCp = 22 kW/ºC
?DH =3520 kW
120
90
60 MCp = 22 kW/ºC
30
0
0 1000 2000 3000 4000 5000 6000
DH (kW)
210 MCp = 70 kW/ºC
Stream 3
MCp = 20 kW/ºC Stream 4
180
DH =3200 kW MCp = 50 kW/ºC
150 DH =2500 kW

120

T (ºC)
Cold Composite Curve

90

60 MCp = 20 kW/ºC

30

0
0 1000 2000 3000 4000 5000 6000
CFernandes 2021 DH (kW)
53
 Build Hot and Cold CC in the same graph

Pinch point
is at the beginning of a cold stream

Pinch point is the zone where there is a minimum

temperature difference between hot and cold temperatures
CFernandes 2021 54
Example 1 – Minimum energy consumption
The two curves may be approximated/moved away, decreasing/increasing the
value ΔTmin, by horizontal translation of the Cold CC;

Setting the ΔTmin value one can determine the minimum amount of external
utilities: HU, CU. 300 Q =1000 kW HU

250

Temperatura (ºC)
200

150
∆Tmin= 20ºC
example1 100
180ºC; 160 ºC
50
QCU=800 kW
0
0 1000 2000 3000 4000 5000 6000 7000

Entalpia (kW)
Example 1 – Composite Curves

Hot Utility = 600 kW

Pinch Point

Cold Utility = 400 kW

CFernandes 2021 56
 Targeting step

Minimum Consumption of Utilities

Graphical method Problem Table

Composite Curves Heat Cascade

CFernandes 2021 57
 From data extraction
Ti Tf MCp T´ i T´ f
(ºC) (ºC) (kW/ºC) (ºC) (ºC)

Streams
1 – Reactor Effluent 270 160 18
CU=5500 kW
2 – Final Product 220 60 22
3 – Reactor Feed 50 210 20
HU=5700 kW
4 – Recirculation 160 210 50

Delta is always constant

 2. Problem Table – Heat Cascade
• Heat Cascade is built by an enthalpy balance in each temperature interval based on the
streams existing in the interval.

• The only modification needed is to ensure that within any interval, hot and cold streams are
ΔTmin apart. This is done by using shifted temperatures, which are set at ΔTmin/2 below for

Temperature shifted, T´ (ºC)

hot streams and ΔTmin/2 above for cold streams temperatures.

Temperature real, T(ºC)

Enthalpy (kW)
 Heat cascade / Problem Table

Shifted temperatures:

TH' =TH DTmin

- Any ∆T > = ∆Tmin
2
D Tmin Guarantee the ∆Tmin for the maximum
TC' = TC + possible amount of heat exchange
2
within each temperature interval

• Both temperatures of a hot stream are set at ΔTmin/2 below

• Both temperatures of a cold stream are set ΔTmin/2 above

 Heat cascade / Problem Table

1. Calculate Shifted temperatures:

TH' =TH DTmin

-
2
D Tmin
TC' = TC +
2

2. Build a table:
Column 1:Temperatures T´by decreasing order

Column 2: Represent streams according to their T´

Column 3: Calculate DTi´for each temperature interval i

Column 4: Calculate DMCpi each interval i

Column 5: Calculate DHi each interval i

 2. Problem Table – Heat Cascade
After the heat balance, each interval will have either a net surplus or net
deficit of heat. The excess of heat from a higher temperature interval could be
supplied to a lower temperature interval.
3.Cumulative enthalpy values
Instead of sending a surplus heat from interval 1 into cold utility, it can be
sent down into interval 2, this is a HEAT CASCADE.
Carry out a first cascade assuming that no heat is supplied to the hottest
interval 1 from hot utility.
Column 6:Calculate the cumulative enthalpies, firstly assuming HU=0

The negative flows between intervals are thermodynamically infeasible. To make it feasible, the more negative
1.
flow (absolute value) must be the HU and a new cascade built.

Column 7: Calculate the cumulative enthalpies, for this new input of HU

This column enables the calculation of the Minimum utility requirement and location of the pinch
 From data extraction
Ti Tf MCp T´ i T´ f
∆Tmin= 20ºC (ºC) (ºC) (kW/ºC) (ºC) (ºC)

Streams
1 – Reactor Effluent 270 160 18 260 150
CU=5500 kW
2 – Final Product 220 60 22 210 50
3 – Reactor Feed 50 210 20 60 220
HU=5700 kW
4 – Recirculation 160 210 50 170 220

Delta is always constant

Heat Cascade example 1 (∆Tmin = 20ºC)
T’ Streams ∆Ti’ ∆MCpi DH =  -  MCp D T’
MCp
(ºC) e MCp (kW/ºC) (ºC) (kW/ºC) i C H i
Cold Hot i

18 ∆MCpi
260
1
∆Hi= -720
220 40 -18

22 ∆Hi=
210
2

∆Hi=
170
4
50 ∆Hi=
150

∆Hi=
60
3
20 ∆Hi=
50
 Example 1 (∆Tmin =20ºC)
T’ Streams ∆Ti’ ∆MCpi
(ºC) e MCp (kW/ºC) (ºC) (kW/ºC) Heat cascade
18
QHUmim= 1000 =
QHu=0 1000
260 1

∆Hi= -720
220 40 -18
720 1720
22
∆Hi= 520 0 – (-720) = 720
210 2
10 52
200 1200

40 30 ∆Hi= 1200
170 4
0 PE: T’=170
50 -1000

20 -20 ∆Hi= -400

150 400
-600
∆Hi= -180
60 3 90 -2
20 -420 580

10 -22 ∆Hi= -220

50
-200 QCUmin = 800
 Example 1 (∆Tmin =20ºC)
T’ Streams ∆Ti’ ∆MCpi
(ºC) e MCp (kW/ºC) (ºC) (kW/ºC) Heat cascade
18 QUQ=0 QUQ = 1000

260 1

∆Hi= -720
220 40 -18
720 1720
22
10 52 ∆Hi= 520 Thot(Pinch)=170+10 = 180ºC
210 2

200 1200
40 30 ∆Hi= 1200
170 4
Pinch T´= 170ºC 20ºC
50 -1000 0
20 -20 ∆Hi= -400
150 PE: T’=170
-600 400 Tcold(Pinch)=170-10 = 160ºC
∆Hi= -180
60 3 90 -2
20 -420 580
10 -22 ∆Hi= -220
50
-200 QUF = 800
Example 1 – Minimum energy consumption
The two curves may be approximated/moved away, decreasing/increasing the
value ΔTmin, by horizontal translation of the Cold CC;

Setting the ΔTmin value one can determine the minimum amount of external
utilities: HU, CU. 300 Q =1000 kW HU

250

Temperatura (ºC)
200

150
∆Tmin= 20ºC
example1 100
180ºC; 160 ºC
50
QCU=800 kW
0
0 1000 2000 3000 4000 5000 6000 7000

Entalpia (kW)
 As ∆Tmin decreases:
• The greater the heat recovered between streams and therefore the
lower the consumption of external utilities;
• The greater the heat transfer area, the higher the equipment cost;

300 ∆Tmin=0ºC
250 QUQ=200 kW

Temperatura (ºC)
∆Tmin optimal depends on the QUF =0 kW
200
optimization of the global costs. ∆Tmin=30ºC
150
QUQ=1400 kW
Without HI
100 QUF =1200 kW

50
0
0 1000 2000 3000 4000 5000 6000 7000 8000
Entalpia (kW)