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OPTIMIZATION WITH
PROCESS INTEGRATION
OUT LINE
• INTRODUCTION
• ENERGY TARGET
• STREAM SPLITTING
• REDUCING NUMBER OF EXCHANGER
• CAPITAL AND TOTAL COST TARGET
• HEAT AND POWER INTEGRATION
INTRODUCTION
Energy conservation is important in process design. In any process flow sheet,
there are several streams that need to be heated and there are some that need to
be cooled. In industrial experience, the calculation of the minimum heating and
cooling requirements reveal significant energy saving. Therefore, energy integration
design procedure is a very beneficial tool and is an important phase in determining
the cost of preliminary design.
There are two laws for heat integration analysis:
The first law (energy conservation law) states that the difference between the
heat available in the hot streams and the heat required for the cold streams is the
net amount of heat that must be removed or supplied. The first law does not
consider the fact that heat can only be transferred from a hot stream to a cold
stream if the temperature of the hot stream surpasses that of the cold stream.
The second law (heat transport law) states that a positive temperature driving
force must exist between the hot and the cold streams
For any heat-exchanger networks, the second law must be satisfied as well as the
first law
ENERGY TARGET
Heat exchanger network analysis is started by identifying heat sources (hot
streams) and heat sink (cold streams) from mass and energy balance
calculation. Let we consider several cases.
CASE-1:
Given the following process streams:
Stream Type Supply temperature Target Temperature CP ΔH
C
0 0
C MW/0C MW
1 Cold 30 100 0.2 14
2 Hot 150 30 0.1 -12
CP is heat capacity flow rate ( CP = F Cp) and ΔH is heat load of a stream.
The positive value of ΔH indicates that the stream requires heat (heat sink)
The negative value of ΔH indicates that the stream evolves heat (heat source)
Design heat exchanger network for minimum temperature difference of 100 C.
ENERGY TARGET
SOLUTION
From the stream data, we plot T-H diagram for cold and hot stream as shown:
QREC=11 MW QH,MIN=3 MW
T
150
1500C
3 MW
30
11 MW
100
40 100
1 MW
40
∆H=14 MW
30 30
QC,MIN=1 MW
∆H=12 MW H
ENERGY TARGET
CASE 2
Consider the following process stream data:
Design heat exchanger network system for minimum temperature difference of 100 C.
SOLUTION
In this case we combine T-H diagram for all cold streams in one curve called: Cold
stream composite curve, and also we combine T-H diagram for all hot streams in one
stream called: Hot Stream Composite Diagram
ENERGY TARGET
CP=0.15 CP=0.25
Preparation of Hot Stream Composite Curve
250
T ∆H ( MW ) H (MW)
200
40 0 0
80 0.15 (80-40)= 6 6
200 (0.15+0.25)(200-80)=48 54
80
250 0.15 (250-200) = 7.5 61.5
230 T ∆H ( MW ) H (MW)
20 0 0
180
140
140 0.2 (140-20)= 24 24
CP=0.3 180 (0.2+0.3)(180-140)=20 44
230 0.3 (230-180) = 15 59
20
CP=0.2
ENERGY TARGET
QREC QHMIN
250
(54,200)
200 QCMIN=10 MW
T
150 QHMIN=7.5 MW
QCMIN
ENERGY TARGET
Heat Recovery Pinch
Heat Sink
Heat Source
H
QCMIN
STEP:
1. Develop Shifted temperature interval from stream data by substracting Tmin/2
from hot stream temperature and adding Tmin/2 on cold stream temperature
2. Calculate a simple energy balance ΔHi in each shifted temperature interval from:
H i CPC CPH Ti
all cold stream all hot stream
Where Hi is the heat balance for shifted temperature interval i and Ti is the
temperature difference across it. If H is positive, then the interval has a net deficit of
heat. If H is negative, then the interval has a net surplus of heat.
3. Construct cascade diagram by cascading any surplus heat down the temperature scale
from interval to interval.
4. Construct grid diagram by matching between cold and hot stream using the following
heuristic for initial (pinch) match: Above the pinch: CP H < CPC
Below the pinch: CPH > CPC
ENERGY TARGET
EXAMPLE:
Construct heat exchanger network based on energy target from the following
stream data for TMIN= 100C
245
235
195
185
145
75
35
25
ENERGY TARGET
STEP 2: Estimate Energy balance in each interval
245 0 MW 7.5 MW
∆H=-1.5
235 1.5 MW 9 MW
∆H= 6
195 -4.5 MW 3 MW
∆H= -1
185 -3.5 MW 4 MW
∆H= 4
-7.5 MW 0 MW
145
∆H = -14
75 6.5 MW 14 MW
∆H = 2
35 4.5 MW 12 MW
∆H = 2
25 2.5 MW 10 MW
COLD UTILITY
ENERGY TARGET
Pinch Match
STEP 4: CONSTRUCT GRID DIAGRAM
Stream ∆H (Above the pinch) ∆H (Below the pinch)
2 -15 -16.5
4 -12.5 -17.5
1 8 24
3 27 0
CP 10 MW
250 8 MW 150
0.15 2 40
200 150
0.25 4 80
140
0.2 180 1
17.5 MW 6.5 MW
140 20
0.3 230 3
7 MW 12.5 MW
7.5 MW
ENERGY TARGET
Pinch Match
STEP 4: CONSTRUCT GRID DIAGRAM
Stream ∆H (Above the pinch) ∆H (Below the pinch)
2 -15 -16.5
4 -12.5 -17.5
1 8 24
3 27 0
8 MW
CP 10 MW
250 150
0.15 2 40
200 150
0.25 4 80
140
0.2 180 1
17.5 MW 6.5 MW
140 20
0.3 230 3
7 MW 12.5 MW
7.5 MW
ENERGY TARGET
HEAT EXCHANGER NETWORK
1
7.5 MW
7 MW 8 MW 6.5 MW
10 MW
12.5 MW 17.5 MW
3
ENERGY TARGET
STREAM SPILTTING
The pinch design method developed earlier followed several rules and guidelines
to allow design for minimum utility (or maximum energy recovery). Occasionally, it
appears not to be possible to create the appropriate matches because one or
other of the design criteria cannot be satisfied. Consider the following cases of the
above-pinch part of a design.
130+a
Case 1:
ΔT=10-a
CP 140
1 140 Stream Splitting
3 140
5 130
130+a
Problem: ΔT< ΔTMIN
Cause: NH > NC
ENERGY TARGET
STREAM SPILTTING
CASE 2:
CP
CP
4
Stream Splitting 1.5
2
2.5
3
2
No match
3
Cause: CPH>CPC
ENERGY TARGET
STREAM SPILTTING
Algorithm
no no
NH≤ NC NH ≥ N C
yes yes
Split a cold Split a hot
stream stream
70 110 20 340 60
NE = NS + NU - 1
ENERGY TARGET
LOOP AND PATH
Loop and Paths provide ways of shifting heat loads through a network.
Loop
A loop is a set of connection that can be traced through a network that starts
from one exchanger and returns to the same exchanger. The existence of a loop
implies that is an extra exchanger in the network. That is, if we break the loop,
we can remove an exchanger.
1 2 1 2 3 4 NE = NS + NU + NL- 1
3 4
Hot
Utility 1 H H
2 3
ENERGY TARGET
LOOP AND PATH
Breaking Loops
Paths:
A path is a connection between a heater and a cooler in a network. We can shift
heat loads along a path.
H H + QE
Q
Q-QE
C C+QE
We merely add an excess amount of heat to the hot utility and subtract it from
another exchanger on the same stream (so that the total heat load for the stream is
unchanged). Of course, we also reduce the heat load on the other stream that passes
through this exchanger. Thus, we must add heat to this stream in either another
exchanger or a cooler
ENERGY TARGET
REDUCING NUMBER OF EXCHANGER
General Rules:
1. The number of exchangers required for the overall process is always less
than or equal to that for the minimum energy network.
2. If the design procedure for the minimum energy network is used, there
will normally be loops across the pinch.
3. We can break these loops by transferring heat across the pinch, but we
will introduce at least one violation of the specified TMIN
4. We can restore TMIN by shifting heat along a path, which increases the
energy consumption of the process.
Hence, we have a procedure for reducing the number of heat exchangers (which
we expect will reduce the capital cost) at the expense of consuming more energy
(which will increase the operating costs). Obviously, we want to find the heat-
exchanger network (as a function of the process flows) which has the smallest
total annual cost.
ENERGY TARGET
REDUCING NUMBER OF EXCHANGER
EXAMPLE
Stream 1 2 3 4
CP 1000 4000 3000 6000
How many
Q=50 loops cross
H=70 the pinch?
Q=240
Break all the
Q=60 loops that
PINCH
cross the
140 130 pinch, and
restore TMIN
C=20
Q=120
C=40
ENERGY TARGET
SOLUTION
Q=50
H=70
First and second
2 Q=240 loop are not
independent. So,
1 Q=60 3 they are
considered as one
PINCH
140 130 independent loop
C=20
Q=120
C=40
ENERGY TARGET
SOLUTION
Break the first loop (loop containing Cooler C=20, the lowest heat load).
The corresponding dependent second loop is also broken.
Q=50+20 Q=50
H=70
Q=240
Q=240-20
Q=60 3
PINCH
140 130
C=20
Q=120
C=20-20 C=40
C=40+20
ENERGY TARGET
Restoring TMIN
We restore the minimum approach temperature at this point in the network
by shifting heat along a path. Since the outlet temperature of stream 1 is
1200F, we want the new inlet temperature of stream 3 to be 1100F. Then we
calculate the amount of heat that must shift along the path to obtain this
intermediate temperature.
(120-QE)x103=3000(110-90)→ QE=60 x 103
Q=70-QE
Q=70
H=70 H=70+QE
Q=220
This exchanger
violate ∆TMIN
Q=60 3 criteria
60+QE
PINCH
130
120 Q=120-QE
Q=120
C=60 C=60+QE 130
120
ENERGY TARGET
Second alternative design. Number of exchanger = 6
Q=10
H=130
Q=220
Q=120 3
PINCH
140 130
110
Q=60
120
C=120
ENERGY TARGET
Breaking the second independent loop (third loop)
QE= 10x103
Q=10
Q=10-QE
H=130
Q=220
Q=220+QE
Q=120 3
Q=120+QE
PINCH
140 130
Q=60-QE
Q=60
120
C=120
ENERGY TARGET
Third alternative design. Number of exchanger = 5
H=130
Q=230
Q=130
PINCH
130
110
Q=50
120
C=120
CAPITAL AND TOTAL COST TARGET
Cost of an exchanger network consists of Capital cost and Utility Cost. Capital
Cost is affected by Number of Exchanger and Heat transfer Area of the Network.
Number of Exchanger:
Heat transfer area required for a heat exchanger network can be estimated by
constructing Balanced Composit Curve. To calculate the network area from the
balanced composite curve, utility streams must be included with the process
streams in the composite curve.The Balanced Composit Curves are divided into
vertical enthalpy intervals.
Qk
Qk Ak
U * TLM k
H
CAPITAL AND TOTAL COST TARGET
ESTIMATING AREA
If U is constant:
1 H k
Anetwork
U
k T
LM , k
U = Overall heat transfer coefficient
If U is not constant:
1 Hot qi Cold q j
Anetwork
k TLM , k
i h j hj
i
EXAMPLE
Given the following process stream and utility data for a chemical
process industry. Estimate the total heat transfer area for heat transfer
network based on energy target (TMIN=100C)
250
T H H 240
40 0 0
80 0.15(80-40)=6 6 239
200
200 (0.15+0.25)(200-80)=48 54
239 0.15(239-200)=5.85 59.85
240 (0.15+7.5)(240-239)=7.65 67.5
250 0.15(250-240)=1.5 69
80
40
230
T H H
20 0 0 180
30 (0.2+1)(30-20)=12 12
140 0.2(140-30)=22 34
180 (0.2+0.3)(180-140)=20 54
230 0.3(230-180)=15 69
140
30
20 20
T
H=12
250 (54,200)
200
150
(6,80)
100
5 4 3 2 1
6
50 7
H
10 20 30 40 50 60 70
CAPITAL AND TOTAL COST TARGET
ESTIMATING AREA
Temperature of hot stream
CP=0.15 h=0.001
CP=0.25 h=0.0008
CP=0.2 h=0.0006
CP=0.3 h=0.0008
CP=1
h=0.001
C qj H
q Ak, m2
Int.Enth.
TLM ,k h
j
i hi
j i
K
1 17.38 1875 1500 194.2
2 25.3 9562.5 2650 482.7
3 28.65 7312.5 5850 459.4
4 14.43 28333.3 23125 3566.1
5 29.38 36666.7 25437.5 2113.8
6 59.86 6666.7 6937.5 227.3
7 34.6 6666.7 6000 366.1
Total 7409.6
CAPITAL AND TOTAL COST TARGET
CAPITAL COST ESTIMATION
1 H qi C qj
Anetwork
k TLM , k
i h j jhj
i i
1 c 1
1 2
b A
c1
c1
b c
(For c1 = c2)
Cost weighting factor: 1 network 1
b2 N b2
ii 1n
Annualized Capital Cost = (Capital Cost)
1 i n 1
For the process in the previous example, determine the total cost of the
heat exchanger network based on energy target. Given the following data:
Heat exchanger capital cost= (40000 + 500 A)$
Steam cost = 120000 ($. MW-1y-1)
Cooling Water cost = 10000 ($. MW-1y-1)
The capital cost is to be paid back over five years at 10% interest.
SOLUTION
7410
7 40000 500
From the previous example: 7
Network heating surface area, A = 7410 m2
Number of HE, N = 7
i1 i n
Annualized HE capital cost =[ 40000 + 500A] 1 i n 1
0.21 0.2 5
= [ 40000 + 500A]
= 10550 + 131.9 A
1 0.2 1
5
CAPITAL AND TOTAL COST TARGET
TOTAL COST ESTIMATION
131.9 Anetwork
Annualized Network Capital Cost = N 10552 N
131.9 x7410
710552
7
Heat Engine:
Steam Turbine
Gas Turbine
QC,min+(QHE-W) QC,min
Diesel Engine
GRAND COMPOSITE CURVE
Grand composite curve is used to analyze heat and power integration
Grand Composite Curve : Shifted Temperature versus Heat Flow
(From Cascade Diagram)
T*
QH,min
QC,min
Heat Flow
STEAM TURBINE
HP Steam
QHP
QHP W
QLP
QFUEL
Boiler
QLP
QC,min
QC,min
STEAM TURBINE
P1
H Turbine Isentropic
H1 Efficiency
P2 H1 H '2
T
H1 H 2
X=1.0
H’2 X=0.9
Mollier Diagram
H2 X=0.85
S
GAS TURBINE
QH,min+W+QLOSS
QFUEL T*EX
QH,min-(QFUEL-W-QLOSS)
T*
W
TEX AIR
Pinch
T*0
QC,min T0 ∆H
Exhaust to atmosphere QLOSS QFUEL-W-QLOSS
QFUEL-W
EXAMPLE-1
The stream data for a heat recovery problem are given in the following table:
Stream
TS TT Heat capacity flowrate
No. Type 0
C 0
C MW K-1
440 21.9
410 29.4
131 23.82
130 1.8
40 0
30 15
T*(0C)
500
HP Steam
400 Heat recovery pocket
W
300
200
100
H (MW)
5 10 15 20 25 30