GrandCompositeCurve

Module04

Lecture12

Module04:Targeting Lecture12:GrandCompositeCurve
Whilecompositecurvesprovideoverallenergytargets,thesedonotindicatetheamountof energythatshouldbesuppliedatdifferenttemperaturelevelsthroughutilities. A graph of net heat flow against shifted temperature can be plotted from the data of the Problem Table (heat cascade) or it can be plotted from shifted temperature level composite curves. This graph is known as the Grand Composite Curve (GCC). It highlights process/utility interface.Itindicatesthedifferencebetweentheheatavailablefromtheprocesshotstreams and the heat required by the process cold streams, relative to the pinch, at a given shifted temperature. Thus, the GCC is a plot of the net heat flow against the shifted (interval) temperature. It is also called residual heat curve. This is also a tool used for setting multiple utility targets and placement of equipment such as heat engines, heat pumps, distillation column, drier, evaporator, furnaces, CHP and to any other unit operation, be it process or utility,whichcouldberepresentedintermsofsourceandsink. ConstructionofGCCusingPTAdata AfoursstreamproblemasdiscussedinLecture11problemTableAlgorithmasgiveninTable 4.2consideredforgenerationofGCC. Table4.2FourstreamproblemforPTAforTminequalto10C. Stream SerialNo. 1 2 3 165 4
1 145

StreamType

CP (KW/K)

ActualTemperatures Ts(0C) 20 170 80 150

Cold 2.25 Hot 3 FromHotUtility Cold 4.25 Hot 2

H=60kW

0 0(60)=60

Shifted Temperatures Tt(0C) Ts(0C) Tt(0C) 135 25 140 60 165 55 FromHotUtility 140 85 145 30 145 25
18.75 78.75 H=+60kW

ThePTAfortheaboveproblemisreproducedinFig.4.8below: H= 3.75kW H=+3.75kW 2 140 60(3.75)=63.75 82.5 H=+82.5kW H=82.5kW 3 63.7582.5=18.75 0 85 H=82.5kW H=+82.5kW 4 18.75(82.5)=63.75 82.5 55 H=+7.5kW H= 7.5kW 5 25 63.757.5=56.25 75 ToColdUtility ToColdUtility (c)Addheatthroughhotutilitytomakeall (b)Transferofcascadesurplusheatfromhigh heatflowpositiveoratleastzero tolowtemperature Fig.4.8 Problemtablecascade

GrandCompositeCurve

Module04

Lecture12

Fig4.9showstheGCCfortheproblemshowninTable4.2.Itisconstructedusingthedata giveninFig.4.8. Shifted Temp.,C Shifted Temp.,C 180 Hotutility=18.75kW 165 18.75kW 165 78.75kW 78.75kW 145 145 140 82.5kW 140 82.5kW Processtoprocess HeatTransfer PinchPoint 0kW 85 85 0kW Processtoprocess HeatTransfer 55 82.5kW 82.5kW 55 25 Coldutility=75kW 75kW 25 H,kW 0 10 30 50 20 40 60 70 80 90 Fig4.9ConstructionofGrandCompositeCurvefromPTAdataforprobleminTable4.2 The values of net heat flow to the top and from the bottom end of the PTA are the heat supplied to and removed from the cascade, and thus indicates the hot and cold utility targets. GCC not only informs about how much net heating and cooling is required, but also provides an opportunity to find at what temperature levels it is needed ? Thus, there is no need to supply all the utility heating at the highest temperature interval. Instead, a considerable amount of it can be supplied at lower temperatures bringing down the utility cost. In GCC the pinch is also easily identifiedasthepointwherenetheatflowis0.AtthispointtheGCCtouchesthetemperature axis. By watching GCC one can easily indentify the nature of problem. For example if pinch point occursatoneendofthetemperaturerangethenitisathresholdproblem.Similarlysingle, doubleandmultiplepinchproblemscanbeidentifiedwithease. ConstructionofGCCusingcompositecurves AnalternateprocedureforconstructionofGCCisthroughcompositecurves.Theconstruction ofGCCusingcompositecurvesisillustratedinFig4.10.Fig4.10(a)showsthehotandcold compositecurvewhereasFig(b)showsthehotandcoldcompositecurvesusingshifted temperatures.Fig.4.10(c)showshowGrandCompositecurvecanbeconstructedusing compositecurvewithshiftedtemperatures.

GrandCompositeCurve

Module04

Lecture12

Actual Temp.,C 170 150 145 140 HotComposite ColdComposite HotPinch 90 Tmin=10C 80 ColdPinch 60 30 H,kW 20 0 100 200 300 400 500 600 (a)HotandcoldCompositecurves Shifted Temp.,C Shifted Temp.,C 180 180 Min.Hotutility=18.75 Min.Hotutility=18.75kW 165 165 kW 78.75kW 78.75kW 145 145 140 140 82.5kW Processtoprocess 82.5kW Hotcomposite HeatTransfer Coldcomposite PinchPoint 0kW 85 85 Processtoprocess HeatTransfer 82.5kW 82.5kW 55 55 Min.Coldutility=75kW Min.Coldutility=75kW H,kW H,kW 25 25 0 0 10 20 30 40 50 60 70 80 90 100 200 300 400 500 600 (b)HotandColdcompositecurvewithshifted (c) GrandCompositeCurve FigConstructionofGrandCompositeCurveusingcompositecurves

GrandCompositeCurve

Module04

Lecture12

PropertiesofGrandCompositeCurve
The GCC provides a graphical representation of the heat flow through the process from hot utility to thosepartsoftheprocessabovethepinchpoint,andfromtheprocessbelowthepinchpointtothecold utility.BecausetheGCCrepresentsheatflowinanidealprocessthereisnoheatflowthroughthepinch point.HoweverinanonidealcaseheatmaypassthroughthepinchpointasshowninFig4.11(b).In Fig.4.11(a) the hot utility transfers heat vertically to the segment ab in the above pinch region. Hence,itisaheatsink.Whereas,inbelowpinchregion,thesegmentacrejectsitsheattothecold utility making it a heat source. For a nonideal case ( Fig 4.11(b)) where 10 kW heat is transferred throughpinch,thehotandcoldutilityamountincreasesby10kWeach. Shifted Shifted Temp.,C Temp.,C

Min.Hotutility=18.75kW 180 165 145 140

Min.Hotutility=28.75kW 180

AbovePinch HeatSink
Processtoprocess HeatTransfer

165 145 140 Processtoprocess HeatTransfer

b
PinchPoint;0kW

a 85
55 25

Processtoprocess HeatTransfer 85

BelowPinch c HeatSource

PinchPoint; 10kW Processtoprocess HeatTransfer

55 25 Min.Coldutility=85kW 0 10 20 30 40 50 60 70 H,kW 80

Min.Coldutility=75kW 0 10 20 30 40 50 60 70

H,kW 80 90

(a) IdealGCC

(b)NonidealGCC Fig.4.11GrandCompositeCurve

TheGrandCompositecurveisnotonlyausefultoolforenergytargetingandselectionofmulti temperaturelevelutilities,butalsohelpsin understandingtheinterfacebetweentheprocess andtheutilitysystem.Itisalsoanusefultooltostudytheinteractionbetweenheatintegrated reactors,evaporatorsandseparatorsandrestoftheprocess.TheregionswheretheGCCbends back on itself and net heat can be exchanged between different temperature intervals are knownaspocketsorreentrants(Theareacoveredbypattern).Notethattheydonotrepresent alltheheatexchangetakingplacebetweenhotandcoldstreams,whichisonlyrevealedbythe composite curves. For the fourstream Example of Table 4.2, the total heat exchange in the processis485kWbutonly73kWoccursinthepockets(65aboveand8belowthepinch).The
profile of the GCC represents residual heating and cooling demands after recovering heat within the process.

GrandCompositeCurve

Module04

Lecture12

GCCforThresholdproblems
TodemonstrateGGCofthresholdproblemstwofourstreamproblemsonegiveninTable4.4 requiringonlyhotutilityandtheotherinTable3.9requiringonlycoldutilityisconsidered. ThesetablesarereproducedfromModule4and3. Table4.4AfourstreamproblemformodifiedProblemTableAlgorithmforTmin=10C Stream Stream Heat Capacity Source Target Number Type FlowRate Temperature Temperature 0 0 (kW/ C) ( C) (0C) 1 HOT 2.5 150 60 2 HOT 8.0 90 60 3 COLD 3.0 20 125 4 COLD 3.0 25 100

(a)

(b) QHmin=75kW QHmin =75kW QCmin=0kW QCmin=0kW Fig.4.12(a)Compositecurves and(b)GCCforthresholdproblemofTable4.4

Table3.9:FourstreamproblemutilitypredictionforTminequalto10C. Nameofthestream SupplyTemperature TargetTemperature CP Ts,C Tt,C kW/C Hot1 190 55 3.5 Hot2 155 40 1.8 Cold1 20 140 2 Cold2 70 150 2.5 H kW 472.5 207 240 200

GrandCompositeCurve (a)

Module04 (b)

Lecture12

QHmin=0kW QHmin =0kW QHmin=239.5kW QCmin=239.5kW Fig.4.13CompositecurvesandGCCforthresholdproblemofTable3.9

Multiple Utility Targeting with the Grand Composite Curve
Several utilities having different temperature levels are used in processes to cool or heat process streams. Common hot utilities used for process heating are steam at different pressures,thermalfluidorhotoil,fluegas,heatrejectedfromheatengines,exhaustheatfrom refrigeration system and heat pump condensers and electrical heating. Similarly cold utilities used are cooling water, air, steam raising and boiler feed water heating, refrigerated fluid, chilled water, heat pump evaporator, reboilers of distillation column and heat engines below thepinch. The utilities can be divided as constant and variable temperature utilities. For example a condensing steam, provides latent heat of condensation at a single temperature. Thus it is a constanttemperature utility. Whereas, the hot flue gas provides sensible heat over a temperaturerangeandthuscanbecalledavariabletemperatureutility. Some utilitiesarea mixofbothtypes.Thecommonexampleofsuchautilityisheatingusingafurnaceaswellas hot gases released from the furnace. Whereas, heating inside a furnace can be termed as constanttemperature,heatingbyfluegasesreleasedfromfurnaceisofvariabletemperature. Tominimizeenergycostthedesignershouldmaximizetheuseofcheaperutilitylevelsandat the same time minimize the use of expensive utility levels. For example a designer should maximizetheuseofLowpressure(LP)steamthanmediumpressure(MP)andhighpressure(HP) steam.Similarly,oneshouldmaximizetheuseofcoolingwaterratherthanrefrigeration. ThetoolthatisusedfortargetingmultipleutilitiesistheGrandCompositeCurve,whichplots processenergydeficit(abovepinch)andenergysurplus(belowpinch)asafunctionofshifted temperature. MultipleconstanttemperatureutilityTargeting

GrandCompositeCurve

Module04

Lecture12

ThesameGCCshowninFig.4.11isreproducedbelow.Inthebasecaseshownbelowitcanbe seenthatthedeficitheatintheabovepinchareaissuppliedbyHighPressure(HP)steamatthe highest temperature level which is higher than Tmin from the next lower temperature level. WiththisheatfromHPsteamtheabovepinchsectionisinheatbalance.However,ifonelooks intothecostaspects,thenhewillrealizethatalowpressure(LP)steamwouldhavebeenaright choicetosupplyheatwhichcostsfarlessthantheHPsteamasshowninFig4.14(b). Shifted Shifted Temp.,C Temp.,C Min.Hotutility=18.75kW Min.Hotutility=18.75kW 180 180 HPsteam AbovePinch AbovePinch 165 165 145 145 140 140 LPsteam UtilityPinch 0kW PinchPoint;0kW PinchPoint; a 85 85 BelowPinch BelowPinch CU3 b CU2 55 55 CU1 UtilityPinch 25 25 Coldutility Min.Coldutility=75kW Min.Coldutility=75kW H,kW H,kW 0 10 20 30 40 50 60 70 80 0 10 20 30 40 50 60 70 80 (b) (a) Fig.4.14MultipleutilitytargetingusingGrandComposite Similarly,inFig.4.14(a)thecoldutilityisprovidedatthelowesttemperatureleveltocoldab segment of GCC. This can be substituted with three cold utilities (CU1,CU2 and CU3) at far higher temperatures to satisfy the cooling requirements ( Fig.4.14(b)). By doing so, one can decreasethecostofcoldutility.However,whenmultipleutilitiesareused,itcreatesmultiple utility pinch and the design becomes somewhat complex. Though use of multiple utility decreases the operating cost of utility it increases the fixed cost of heat exchange. Thus, the designer should strike a balance between fixed and operating costs while suggesting multiple utilities. The opportunity to use multiple utilities largely depends on the nature of the GCC curve. To give a feel how multiple utilities are employed Fig.4.15 is drawn. Fig.4.16 shows how multipleutilitycanbetargetedthroughcompositecurveandhowutilitypinchesarecreatedin multipleutilitytargeting.

GrandCompositeCurve

Module04

Lecture12

Boiler Boiler Feed Steam Water Power Turbine Fuel HPsteam MPsteam LPsteam VeryLowPressuresteam Boilerwaterheating Fig.4.15ShowshowmultipleutilitiesareplacedinGCC T T HPSteam MPsteam HPSteam LPSteam ProcessPinch ProcessPinch Tmin Tmin Tmin Tmin Tmin UtilityPinch VLPsteam H CU H CU (b) (a) Fig.4.16Multipleutilitytargetingusingbalancedcompositecurveandcreationofutilitypinch VariabletemperatureutilityTargeting Variabletemperatureutilitiestransfersensibleheatandthereforeitstemperatureincreasesor decreasesdependingonwhetheritreceivesheatorgivesheat.Commonexamplesarehotoil circuits, exhaust gases from CHP systems, flue gases from boilers, boiler feed water being preheatedandcoolingwater.buttheutilityitselfplotsasaslopinglineinsteadofahorizontal oneThecorrectplacementprincipleare:hotutilitiesshouldbeusedabovethepinchofthe GCCandcoldutilitiesbelow.Inthiscase,theutilityplotsareslopinglineinsteadofahorizontal one(asinthecaseofconstanttemperatureutility). Forsuchutilities,thereisachoiceofmaximumtemperature,andonehastoselectitbasedon fixedandoperatingcosttradeoffs.Further,itshouldbecheckedwhethertheutilitystreamis usedonceonly(e.g.fluegaswhichisrejectedtoatmosphereaftertransferofheat)orre circulated(e.g.hotoilcircuitswherethehotoilaftertransferringheatisreturnedtoafurnace

GrandCompositeCurve

Module04

Lecture12

forreheatingorcoolingwatersystemswhereaftercoolingahotstreamitissenttocooling towertorejectitsheat). Fig.4.17(a)showsrecirculatedhotoilashotutilityandFig.4.17(b)showsgasturbineexhaust asoncethroughhotutility.Itshouldbenotedthatinaoncethroughhotutilityalltheheatis nottransferredtothesystemandapartofitisrejectedtoatmospherewhichisafunctionof itsinlettemperature. T Hotoil Return H Fuel (a) Useofhotoilashotutility Flue gas Fuel Propulsion Combustion PowerCoupling Flue Chamber Generator
T
gas
Compressor Atmospheric airintake Turbine Turbine Exhaust

Stack (b) UseFluegasfromgasturbineashotutility StackLoss

Fig.4.17 Variabletemperatureutilitytargeting

Mixed utility targeting Bothtypesofutilitiessuchasconstanttemperatureandvariabletemperatureutilitiescanbe appliedagivenGCCfortargeting.Fig.4.18showsasuchexamplewhereconstanttemperature hotutilitiesintermsofsteamatdifferentpressureisusedintheabovepinchregionanda mixtureofbothtypesofutilities(Generationofstream,boilerwaterpreheating,vapor superheatingandcoolingwithcoldwater)isemployedinthebelowpinchregionoftheGCC.

GrandCompositeCurve

Module04

Lecture12

Shifted Temp.,C

QHmin HPsteam

Above Pinch Pinch Below Pinch LPstream raising Boiling Cooling BFW Super Heating Preheat Water QCmin H,kW Fig4.18 MixedutilitytargetingusingGCC HeatRecoveryfromthepocketsofGCC
IfthereisenoughpotentialintermsofTorloadinapocketofGCC,itcanbeutilizedtosave utility.ThisisshowninFig.4.19(a)&(b).Fig.4.19(a)showsthebelowpinchregionofaGCC.It showsthatthereisasubstantialscopetosaveandgenerateutilityusingthispocket.Fig.4.19(b) shows that MP steam can be raised using a part of this pocket. To maintain a heat balance insidethispocketLPsteamisprovidedfromtheoutsideatalowertemperature.

MPsteam

GrandCompositeCurve Shifted T,C

Module04 Shifted T,C

Lecture12

BelowPinch

MPstreamraising Pocket LPsteam Sink Profile Source H,kW Profile (a) (b) Fig.4.19UtilizationofGrandCompositeCurvepocket IntegrationofEquipmentwithBackgroundGCC

Source Profile

BelowPinch

H,kW

TodemonstratetheintegrationofMultipleEffectEvaporator(MEE)systemwithabackground process given in Fig. 4.18, Fig.4.20 is drawn. Fig.4.20 shows that a part of HP steam can be replacedbyLPsteamtoreducetheutilitycost.However,therecanbeotheralternativewhich HPsteamforanamountofQHminbutalsointegratesanequipmentorasetofequipmentwith theGCCsothattheseequipmentfunctionwithouttheneedofanyutility.Inotherwordsthese rideontheGCCfreeofcost.SuchanexampleisdemonstratedinFig.4.20Itcanbeseenthat the above pinch region of the GCC offers large driving force( T). This can be utilized to integrateasixeffectMEEsystemintotheupperpartoftheGCCasdemonstratedinFig.4.20 Though in this arrangement QHmin amount of HP steam is supplied to the GCC which completely satisfy the requirement of the upper part of GCC, in addition it also satisfies the steamrequirementforasixeffectMEEsystem.ThustheMEEsystemrunsalmostfreeofcost onthebackgroundGCC.

ReducedPocket

GrandCompositeCurve

Module04

Lecture12

QHmin Shifted Temp.,C HPsteam Eff.05 Eff.06 Eff.04 Eff.03 Eff.02 Above Eff01 Pinch Pinch Below Pinch QCmin H,kW Fig.4.20 IntegrationofevaporatorwithbackgroundGCC References 1. http://ectcvarennes.nrcan.gc.ca
2. Linnhoff March, Introduction to Pinch Technology Targeting House, Gadbrook Park, Northwich,Cheshire,CW97UZ,England 3. ChemicalProcessDesignandIntegration,RobinSmith,JohnWiley&SonsLtd. 4. IanCKemp,PinchAnalysisandprocessintegration,auserguideonprocessintegration foreffectiveuseofenergy,IChemE,ElsevierLimited,2007.