Heat integration

The purpose of heat integration is to create a heat exchange network, optimally

matching hot and cold streams, if this is possible, in order to minimize utility
consumption, as the minimum number of heat exchangers is specified.
There is a set of hot process streams to be cooled and a set of process streams to be
heated. In the Table 1, inlet and outlet temperatures, T (difference of inlet and outer
temperature of the stream, absolute value) and pressure of streams passing through
the heat exchangers. In Table 2 the flow rates, heat capacities and available ulitities of
streams are depicted.
The available utility of a stream is given by eq. (1)

Q=Fc p T

(1)

,where Q is the available utility of the stream, F is the flow rate of the stream,
the heat capacity of the stream and
temperature of the stream.

is the difference of inlet and outer

cp

is

Stream

Cold_1
(C_1)
Cold_2
(C_2)
Cold_3
(C_3)

Cold_4
(C_4)

Cold_5
(C_5)

Cold_6
(C_6)

Hot_1
(H_1)

Hot_2
(H_2)
Hot_3
(H_3)

Hot_4
(H_4)

Hot_5
(H_5)

Unitstream
passing
through it
Heat
exchange
r 1 (E_1)
Heat
Exchange
r 2 (E_2)
Reboiler
of 1st
Distillatio
n Column
(R_1)
Reboiler
of 2nd
Distillatio
n Column
(R_2)
Reboiler
of 3rd
Distillatio
n Column
(R_3)
Reboiler
of 4th
Distillatio
n Column
(R_4)
Condense
r of 1st
Distillatio
n Column
(Cd_1)
Heat
Exchange
r 3 (E_3)
Condense
r of 2nd
Distillatio
n Column
(Cd_2)
Condense
r of 3rd
Distillatio
n Column
(Cd_3)
Condense
r of 4th
Distillatio
n Column
(Cd_4)

Inlet
Temperature
(K)

Outlet
Temperature
(K)

T (K)

Pressure of
stream (atm)

344

363

19

1,1

306

363

60

1,1

443

444

0,22

448

449

1,1

458

459

1,1

477

478

1,1

360

359

0,12

444

333

111

1,1

332

331

425

424

456

455

Stream
Cold_1
(C_1)
Cold_2
(C_2)
Cold_3
(C_3)
Cold_4
(C_4)
Cold_5
(C_5)
Cold_6
(C_6)
Hot_1
(H_1)
Hot_2
(H_2)
Hot_3
(H_3)
Hot_4
(H_4)
Hot_5
(H_5)

Flow rate (kg/h)

187062,2

Heat Capacity
0,001959

Available Utility
6961,4708

337237,5

0,001882

36184,3524

59048,6

1,194982

70562

38821,99

0,621315

24120,7

32110,62

2,191714

70377,3

996,7703

38,13145

38008,3

59048,6

0,00218

14308,233

139816,1

0,437739

61202,9

20226,61

0,684356

13842,2

6711,374

10,42718

69980,7

31113,85

1,230118

38273,7

To create the Heat Exchanger Network (HEN), the pinch-point should be determined. It
is chosen T= 10 K. This means that in all cases the inlet temperature of cold stream
and the outlet temperature of hot steam, as well as the outlet temperature of hot
stream and the inlet temperature of cold stream (the two combining streams) should
differ at least T= 10 K, otherwise the heat exchange of these streams is impossible.
A list of intervals is created, there are two columns, a hot and a cold one. The
temperatures (inlet and outlet) of streams are noted and at these temperatures either
add or subtract T to find the corresponding one in hot or cold column respectively.
Then vertical lines showing the stream temperatures are plotted. This process is
depicted in Table 3.

Following step is to calculate the heat contents for hot and cold streams using eq. (2)

(2)

Q=Fc p(T 2T 1)

, where F is the flow rate of the stream,

cp

is the heat capacity of the stream,

T2

is the outlet temperature of cold streams and inlet temperature for hot streams and

T1

is the inlet temperature of cold streams and outlet temperature of hot streams.

In the intervals where there two or more streams, eq. (3) is used.
2

j=1

j=1

Qi= Q j= F jc p j( T 2T 1 )i ,i=1,20 j=1,2

, where

Qi

is the number of intervals, j is the number of streams in each interval,

is the available heat in each interval,

in this interval,
respectively and

Fj

and

( T 2T 1 )i

Qj

is the available heat of each stream

c p j are the flow rate and heat capacity of j-stream

is the difference of outlet and inlet temperature of the

streams in this interval. So, the available heat for hot streams and the required heat
for cold streams are calculated. The next step is to add the available heat interval by
interval, starting from the top. The top value is zero, as there is nothing to be added.
The Cascaded heat for hot and cold streams are found. Following step is the
calculation of the grand composite net heat. This is derived from the subtraction of
required heat values from the corresponding of available heat. Also the grand
composite cascade net is estimated. It can be found either by subtracting the
cascaded heat of cold streams from the cascaded heat of hot streams or by adding the
grand composite net heat starting from the top where the value is zero.

From Table (the table above) it can be seen that the highest absolute value in the
grand composite cascaded heat is -164794,6 MJ/h. So, adding this value in the grand
composite cascades heat column, a new column- Grand composite adjascent cascade
heat column- is derived, as it can be seen in Table (down) There are no negative
values and there are two values of zero which indicate the Pinch Point (P.P.)

As it can be seen from Adajascent cascade heat column of Table (above), by doing
heat integration 164794,6 MJ are needed for heating utilities and 116188,1 MJ for
cooling.
Initially, from Table (it is the table that mentions duties of heat exchangers, reboilers
from Pro) the total cold utilities can be found by adding the duties of E_1, E_2, R_1,
R_2, R_3 and R_4 that come from ProII and the total hot utilities by adding the duties
of Cd_1, E_3, Cd_2, Cd_3 and Cd_4 that come from ProII as well.
So, the needed energy for hot utilities is 248118,61 MJ and for cold utilities is
197607,4 MJ. It can be derived from eq. () that by creating Heat Exchanger Network
(HEN), the energy that can be saved for cold utilities is 0,412 or 41,2 % and for hot
utilities 0,336 or 33,6%.

Esaved =

QProII QHI
Q ProII

, where

Esaved

(3)

is the energy saved by doing heat integration,

needed for cooling or heating according to ProII and

QHI

QProII

is the energy

is the energy needed for

cooling or heating according to heat integration.

Defining the P.P. two sides are specified, one above the P.P. and one below the P.P..
Heat integration of streams can be done for streams that are on the same side.
As it can be seen from Table (above), below the P.P. there are 4 hot streams and 2 cold
streams, Information of these streams are shown in Table (below)
Stream

C_1
C_2
H_1
H_2
H_3
H_4

Inlet
Temperature
(K)
344
306
360
444
332
425

Outlet
Temperature
(K)
363
363
359
333
331
424

Available
Utility
6961,4708
36184,3524
14308,233
61202,9
13842,2
69980,7

F* c p
366,39
634,81
61202,9
128,9
13842,2
69980,7

Doing heat integration, T= 10 K should be satisfied as it is mentioned before. A

proposal of Heat integration is shown in Figure 1.

FIGURE?????????????????????????????????
As it can be seen from Figure 1, the C_1 passing through E_1 can be combined with
H_2 passing through E_3.
FIGURE WITH PROCESS???????????????????????????

The C_1 is completely satisfied but the H_2 is not. The available heat of C_1 can cool
H_2 till 389,99 K, as it can be estimated by eq. (5). To find the temperature that the
stream reaches after integration, the drop or increase of temperature because of the
stream heat exchange should be firstly calculated, eq. (4)

T k=

Qj
Fk c pk

(4)

, where k is the stream that is not fully satisfied, j is the fully satisfied stream,
is the drop or increase of temperature of not fulfilled stream,
energy of stream that is fully satisfied,

Fk

and

c pk

Qj

Tk

is the available

are the mass flow rate and

heat capacity of not fulfilled stream respectively. The temperature of not fulfilled
stream after integration is calculated by eq. (5) in case of hot stream and by eq. (6) in
case of cold stream.

T new =T inlet T
, where

T new

(5)

is the temperature after the integration,

temperature of the stream and

T inlet

is the inlet

is the drop of temperature because of

integration

T new =T inlet + T
, where

T new

(6)

is the temperature after the integration,

temperature of the stream and

T inlet

is the inlet

is the increase of temperature because of

integration.
In order for H_2 to be fully satisfied an external heat exchanger is needed with duty
7346,01 MJ. This duty is estimated by eq. (1), where T is the difference between
temperature after heat integration or inlet temperature and the desired outlet
temperature. From Figure (1) , it can be also seen that C_2 passing through E_2 is
combined with H_4 passing through Cd_3. The C_2 is completely fulfilled, while H_4 is
cooled to 424,46 K as it can be estimated by eq. (4) and (5). An external heat
exchanger with utility equal to 32191,1 MJ/h is also needed to drop the temperature to
424 K ( T =0,46 K ). The duty of external heat exchanger is estimated using eq. (1).
External heat exchangers for H_1 and H_2 are also needed. Utilities of these
exchangers are estimated by eq. (1) and are equal to 61202,9 MJ/h and 13842,2 MJ/h
respectively, which are actually the same amount of energy as their available heat.

From Table (including everything), above the pinch point, there are 4 cold streams and
1 hot stream. In Table (below) available utilities, inlet and outlet temperatures and F*

cp

are given

Stream

C_3
C_4
C_5
C_6
H_5

Inlet
Temperature
(K)
443
448
458
477
456

Outlet
Temperature
(K)
444
449
459
478
455

Available
Utility

F* c p

70562
24120,7
70377,3
61202,9
38273,7

70562
24120,7
70377,3
38008,3
38273,7

T =10 K should be satisfied for heat integration. The only possible heat integration
is between C_3 passing through R_1 and H_5 passing through Cd_4. The hot stream is
totally satisfied as it needs much less energy than the available heat of cold stream.
The temperature of C_3 after integration is found by eq. (4) and (6) to be equal to
443,54 K. To estimate the utility of the external heat exchanger used to fully satisfy
C_3, eq. (1) is used. So, the utility needed for C_3 to be fulfilled is 32458,52 MJ/h,
which is the needed energy to increase the temperature from 443,54 K to 444 K
(T=0,46 K).
After heat integration, it can be seen that above the P.P, 164965,12 MJ/h are needed
for heating, which is the energy that cold streams need and below the P.P. 114582,21
MJ/h are needed for cooling, which is the energy that hot streams need. The hot
stream above the P.P. and the cold streams below the P.P. have already been satisfied.

THEY ARE NOT EXACTLY THE SAME AS THESE ON THE TABLE!!!!!!!

UNITS OF C_P???????