LECTURE DAY 2

Timo Laukkanen
 What was important in
Lecture 1
Process Integration/Heat Exchanger Network
Synthesis (HENS) is an important step in
process design
Energy saving is very often also
economically feasible
Energy saving in industry is a major
contributor in CO2 savings in the next 40
years
CC (Composite Curves)
Course arrangements
What is important in Lecture
2
Problem Table Algorithm (PTA)
Heat Cascade
Grand Composite Curve (GCC)
Pinch violations
Stream grid
Maximum Energy Recovery (MER)
Network
Targeting for minimum number of Units
Numerical Method(s) for
Energy Targets

Problem Table Algorithm,

Heat Cascade,
Grand Composite Curve
 Step 1 (adjust temperatures)
Hot streams: T*hot = Thot - Tmin
Cold streams: T*cold = Tcold + Tmin

Tmin = 50C

m cp m cp
Tsupply Ttarget T*supply T*target
(kW/K (kW/K
(C) (C) (C) (C)
) )
H1 400 120 1.0 H1 375 95 1.0
H2 250 120 2.0 H2 225 95 2.0
C1 160 400 1.5 C1 185 425 1.5
C2 100 250 1.3 C2 125 275 1.3
 Step 2 (temperature intervalls)
m cp
T*supply T*target 425
(kW/K
(C) (C) C
)
H1 375 95 1.0 T=50C
H1
H2 225 95 2.0 375 TI 1
C1 185 425 1.5 C
C2 125 275 1.3
T=100
C
TI 2 H2
275
C
T=50C
225 TI 3 C1
C
T=40C C2
185 TI 4
C
T=60C
 Step 3 (enthalpy balance)

425
C
H1
T=50C H1 = 50 * (0.0 - 1.5) = -75
1.0
375 TI 1
C
T=100 H2 = 100 * (1.0 1.5) = -50
C H2
TI 2 2.0
275
C
T=50C H3 = 50 * (1.0 1.5 - 1.3) = -90
225 TI 3 C1
C 1.5
T=40C H4 = 40 * (1.0 + 2.0 1.5 1.3) = 8
C2
185 TI 4 1.3
C
 Step 4 (cascade the heat flow)
425 215 Hot
C 140 Utility
-75
-75
375 TI 1 90
C -
125
-50
0 Pinch Point
275 TI 2
C -
215
-90 8
225 TI 3
C -
207 110
8 Cold
TI 4 Utility
185 200
C -
105
102
200
125 TI 5
 Summary
Problem Table Algorithm
Adjust (shift) the temperatures
Find the temperature intervals
Calculate the enthalpy balance for
each interval
heat surplus (+) and deficit (-)
Cascade the enthalpy
add large deficit at the top
Make the heat cascade
thermodynamically feasible
 Grand Composite Curve
T(C)

425 215
C 140

375 TI 1 90
C

0
275 TI 2
C
8
225 TI 3
C 110

185 TI 4 200
C
Q (kW)
200
125 TI 5 50 100 150 200
Grand Composite Curve (GGC)
T(C)

HP steam

Visualizes the LP steam

surplus and deficit Other process
heat at different
temperature
intervals Heat integration possibility
Provides an visual between processes
tool for integrating
Different utilities
Different processes
Heat pumps
Other
thermodynamic
cycles

Q (k

50 100 150 200

3 Pinch Rules For Maximum
Energy Recovery

Pinch Violations
Heat transfer through the Pinch
T QS, min+ Q

Heat Deficit

pinch temperature Q
Q?

Heat Surplus

QW, min+ Q
Q
Cooling above and heating below
the Pinch
T QS, min+ Q

Heat Deficit
Q

pinch temperature

Heat Surplus

QW, min+ Q
Q
 Summary
3 Pinch Rules
Never transfer heat through the pinch
Penalty: Increased both hot and cold utility
Never cool (with external cooling) above
the pinch
Penalty: Increased hot utility
Never heat (with external heating)
below the pinch
Penalty: Increased cold utility
Heat Exchanger Network
Design

Stream Grid,
MER Network
 Stream Grid
m cp Tmin = 50C,
Tsupply Ttarget
(kW/K Tpinch = 225C

Tpinch, cold = 200C

Tpinch, hot = 250C
(C) (C)
) Qh = 225 kW, Qc = 200 kW
H1 400 120 1.0
H2 250 120 2.0
C1 160 400 1.5
C2 100 250 1.3

H1 1.0

H2 2.0

1.5 C1

1.3 C2
 Stream Matches
Qh = 225 kW, Qc = 200 kW

Tpinch, cold = 200C

Tpinch, hot = 250C
QH1 = 1.0 * (400 250) = 150kW
QC1 = 1.5 * (400 200) = 300 kW

Q = 150 kW
400C 120C
H1 1.0

120C
H2 2.0

Q = 150 kW
400C 160C
1.5 C1
Q = 65 kW
250C 100C
1.3 C2
QC2 = 1.3 * (250 200) = 65 kW
 Stream splitting
Qh = 225 kW, Qc = 200 kW

Tpinch, cold = 200C

Tpinch, hot = 250C

QH = 130kW QH = 91kW QH = 169kW

QC = 40kW QC = 20kW QC = 130kW
Q = 40 kW Q = 90 kW
120C
H1 1.0
Q = 20 kW
0.7

1.3 Q = 130 kWQ = 110 kW

120C
H2 2.0
1.0

0.5 160C
1.5 C1

100C
1.3 C2
 Summary
Stream Grid and MER-Network
Draw the Stream Grid
draw the pinch(es)
draw the streams above and below the pinch
Match streams starting at the pinch
(m cp)out >= (m cp)in
Split streams if necessary
Calculate the heat exchanger duty
Remember hot and cold streams have
different pinch temperature!