Heat Exchanger Network

Synthesis, Part II

Ref: Seider, Seader and Lewin (2004), Chapter 10

1 Advanced HEN Synthesis -7

 Part Two: Objectives
This Unit on HEN synthesis serves to expand on
what was covered last week to more advanced
topics.
Instructional Objectives - You should be able to:
Identify and eliminate heat loops in an MER
design
Use stream splits to design for Umin and MER
Design a HEN for Threshold Problems

2 Advanced HEN Synthesis -7

 Loops and Splits
The minimum number of units (Umin) in a network:
UMin = NStream + NUtil 1 (Hohman, 1971)
A HEN containing UHEX units (UHEX Umin) has (UHEX Umin)
independent heat loops.
H1 C

H C1

H C2
The HEN above has 2 heat loops
Normally, when heat loops are broken, heat flows across
the pinch - the number of heat exchangers is reduced, but
the utility loads are increased.
3 Advanced HEN Synthesis -7
 Class Exercise 4 (Linnhoff and Flower, 1978)
Example:
Stream
TS TT H CP
(oC) (oC) o
(kW) (kW/ C)
H1 180 40 280 2.0
H2 150 40 440 4.0
C1 60 180 360 3.0
C2 30 130 260 2.6
Tmin = 10 oC.
Step 1: Temperature Intervals
(subtract Tmin from hot temperatures)
Temperature intervals:
180oC 170oC 140oC 130oC 60oC 30oC

4 Advanced HEN Synthesis -7

 Class Exercise 4 (Contd)

Step 2: Interval heat balances

For each interval, compute:
Hi = (Ti Ti+1)(CPHot CPCold )
CPHot
Interval Ti Ti Ti+1 CPCold Hi
1 180 10 3.0 30
2 170 30 1.0 30
3 140 10 3.0 30
4 130 70 0.4 28
5 60 30 3.4 102
6 30

5 Advanced HEN Synthesis -7

 Class Exercise 4 (Contd)
Eliminate infeasible

Step 3: Form enthalpy QH

Assume
QH = 0
(negative) heat transfer
QH = 60
cascade. o
T1 = 180 C

H = -30

Q1 -30 30
o
T2 = 170 C

H = -30

Q2 -60 0
o
T3 = 140 C

H = 30

Q3 -30 30
o
T4 = 130 C

H = 28

Q4 -2 58
This defines: T5 = 60oC
Cold pinch temp. = 140 oC H = 102
QHmin = 60 kW
QC 100 160
QCmin = 160 kW T6 = 30oC

6 Advanced HEN Synthesis -7

 Class Exercise 4 (Contd)
MER Design above the pinch: CP
180o 150o
H1 2.0
UMin,MER = NStream + NUtil - 1
=2+11
160o 140o
180o
H C1 3.0 =2
60 60
MER Design below the pinch: CP
150o 110o 40o 2.0
UMin,MER = 4 + 1 1
H1
=4
H2
150o 140o 110o 80o
C
40o 4.0 MER design below
160 pinch has 6
140o 126.67o 100o 60o
C1 3.0
exchangers!
40 80 120
i.e. There are two
130o 83.85 o
30o loops below pinch.
C2 2.6
120 140

7 Advanced HEN Synthesis -7

 Class Exercise 4 (Contd)
Complete MER Design CP
180o 150o 110o 40o
H1 2.0

150o 140o 110o 80o 40o 4.0

H2 C
160
o o o o o
180 160 140 126.67 100 60o
H C1 3.0
60 60 40 80 120
130o 83.85o 30o
C2 2.6
120 140
However, UMin = NStream + NUtil 1
= 4 + 2 1
= 5
The MER network has 8 units. This implies 3 independent heat
load loops. We shall now identify and eliminate these
loops in order to design for UMin
8 Advanced HEN Synthesis -7
 Class Exercise 4 (Contd)
Identification and elimination of 1st loop:
Tmin violation CP
180o 110o
150 110o 40o
H1 2.0

150o 140o 110o 80o 40o 4.0

H2 C
160
160
o o o o o o
180 160 140
113.33 126.67 100
100 60o
H C1 3.0
60 60
140 40
40 80 120
130o 83.85o 30o C2 2.6
120
120 140

To reduce the number of units, the 80 kW exchanger

is merged with the 60 kW exchanger. This breaks the
heat loop, but also creates a Tmin volation in the
network:

9 Advanced HEN Synthesis -7

 Class Exercise 4 (Contd)
Identification and elimination of 1st loop (Contd):
To restore Tmin, the loads of the exchangers must be
adjusted along a heat path by an unknown amount x. A
heat path is a path through the network that connects
heaters with coolers.
Tminviolates CP
o
This Tmin
violation
180o 110
110o 40 o
40o
H1 2.0
o
150o 140o 110o 80 o
80o 40
40o 4.0
H2 C
160+ x
160
o o o o o
180 160 113.33 100 60o
60
H C1 3.0
6060
+x 140 x
140 40 120
130o 83.85oo
83.85 30
30o
o
C2 2.6
120 x
120 140
140+ x

10 Advanced HEN Synthesis -7

 Class Exercise 4 (Contd)
Identification and elimination of 1st loop (Contd):
Performing a heat balance on H1 in the exchanger which
exhibits the Tmin violation:
140 - x = 2(180 - 113.33 - Tmin) x = 26.66
CP
Tminviolates
This Tcorrected
violation min
180o 110oo
123.33 40oo
40
H1 2.0

150o 140o 116.66

110o
o
80o
86.66 o
40oo
40
H2 C 4.0
160
186.66
+x
o o o
151.1
180 160 113.33oo
113.33 100 o o
60o
60
H
H C1 3.0
60 +x
86.66 140 x
113.33 40
o o
120120
130o 94.1
83.85 30o
C2 2.6
120 x
93.33 166.66
140 + x

This is called energy relaxation

11 Advanced HEN Synthesis -7

 Class Exercise 4 (Contd)
Identification and elimination of 2nd loop:
CP
o
180o 123.33o 40oo
40
H1 2.0

150o 140o 126.66o

116.66 86.66o 40o
40 o
H2 C 4.0
186.66
180 o 151.1o 113.33 o
100 o
60o
H
H C1 3.0

86.66 113.33 40 160

120
130o 94.1oo
94.1 30
30
o
C2 2.6
2.6
93.33
93.33
93.33 166.66
166.66
166.66

Since there is no Tmin violation, no adjustment of the

loads of the exchangers is needed - we reduce the
number of units by one with no energy penalty.

12 Advanced HEN Synthesis -7

 Class Exercise 4 (Contd)
Identification and elimination of 3rd loop:

CP
180o 123.33o 40oo
40
H1 2.0

150o 126.66o 86.66

o
40o
H2 C 4.0
186.66
180o 151.1o o
113.33 60oo
H C1 3.0
86.66 113.33 160 o
o
130
oo
94.1
94.1 30o
30
C2 2.6
93.33
93.33 166.66
166.66

Shifting the load of the smallest exchanger (93.33 kW)

around the loop, the network is reduced to

13 Advanced HEN Synthesis -7

 Class Exercise 4 (Contd)
Identification and elimination of 3rd loop:

CP
180o 170o 40o
H1 2.0

150o 86.66o 40o

H2 C 4.0
Tmin violation 186.66+x
180 o 151.1o 144.44o 60o
H C1 3.0

86.66+x 20 253 x
130 o 30o
C2 2.6
260

We use the heat path to restore Tmin:

253.33 - x = 3(150 - Tmin- 60) x = 13.33

14 Advanced HEN Synthesis -7

 Class Exercise 4 (Contd)
Therefore Umin Network is:
CP
180o 170o 40o
H1 2.0

150o 90o 40o

H2 C 4.0
200
o
180 146.67o 140 o
60o
H C1 3.0
100 20 240
130 o 30o
C2 2.6
260

15 Advanced HEN Synthesis -7

 Loop Breaking - Summary
Step 1:
Perform MER Design for UHEX units. Try and ensure that
design meets UMin,MER separately above and below the
pinch.
Step 2:
Compute the minimum number of units:
UMin = NStream + NUtil 1
This identifies UHEX Umin independent heat loops, which
can be eliminated to reduce U.
Step 3:
For each loop, eliminate a unit. If this causes a Tmin
violation, identify the heat path and perform energy
relaxation by increasing the duties of the cooler and
heater on the heat path.
Loops improve energy recovery and heat load flexibility at the
cost of added units (>Umin)

16 Advanced HEN Synthesis -7

 Stream Split Designs
Example. o
CP
o 300
500
H1 3
480o 180o
C1 1
460o 160o
C2 1

QHmin = 0 UMin = 2 QCmin = 0

Option 1.
CP
o o o o
500 400 327 300
H1 C 3
480o 80 180o
C1 1
460o 300
380o 160o
H C2 1
80 220

17 Advanced HEN Synthesis -7

 Stream Split Designs (Contd)
Option 2. Loops
CP
o o o o o
500 480 440 360 300
H1 3
480o 420o 180o
C1 1
460o 60 340o 240 160o
C2 1
120 180
Option 3. Stream Splitting CP = 1.5
500o
CP
o o
500 300
H1 3
500o
480o 180o
C1 1
460o 300 160o
C2 1
300
18 Advanced HEN Synthesis -7
 Loops vs. Stream Splits
Loops:
Improved energy recovery (normally)
Heat load flexibility (normally)
U > UMin (by definition)
Stream Splitting:
Maximum Energy recovery (always)
Branch flowrate flexibility (normally)
U = UMin (always)

Stream splitting is a powerful technique for better

energy recovery
BUT - Dont split unless necessary
19 Advanced HEN Synthesis -7
 Stream Splitting Rules
1. Above the pinch (at the pinch):
Cold utilities cannot be used (for MER). So, if NH > NC,
MUST split COLD streams, since for feasibility NH NC
Feasible matches must ensure CPH CPC. If this is not
possible for every match, split HOT streams as needed.
If Hot steams are split, recheck

2. Below the pinch (at the pinch):

Hot utilities cannot be used (for MER). So, if NC > NH,
MUST split HOT streams, since for feasibility NC NH
Feasible matches must ensure CPC CPH. If this is not
possible for every match, split COLD streams as needed.
If Cold steams are split, recheck

20 Advanced HEN Synthesis -7

 Class Exercise 5
Design a hot-side HEN, given the stream data below:
CP

o o
200 100
H1 5

H2
H2
150o
100o
4
190o T1 x 90o
C1 10

T2 500
10 x
200

Solution:
Since NH > NC, we must split C1. The split ratio is dictated by
the rule: CPH CPC (necessary condition) and by a desire to
minimize the number of units (tick off streams)

21 Advanced HEN Synthesis -7

 Class Exercise 5 (Contd)
CP
o
200o 100
H1 5
150o 100o
H2 4
190o T1 x 90o
C1 10

T2 500

10 x
200

x is determined by the following energy balances:

x(T1 90) = 500
(10 x)(T2 90) = 200
subject to: 200 T1 Tmin = 10
150 T2 Tmin = 10
Best to make T1 = T2 . Here, this is not possible. Why?
We shall make T2 = 140 (why?)

22 Advanced HEN Synthesis -7

 Class Exercise 5 (Contd)
A possible solution is therefore:
(10 x) (140 90) = 200 x = 6
T1 = 90 + 500/x = 173.33 (satisfies constraint)
Complete solution is:
CP
o
200o 100
5
H1
150o 100o
H2 4
190o 173.3o 6
5 90o
H 10
C1
300 130o
140 500 4
5
H
300 200

This is an MER design which also satisfies UMin (UMin = 3).

23 Advanced HEN Synthesis -7

 Threshold Problems
Networks with excess heat supply or heat demand may have
MER targets with only one utility (i.e., either QHmin = 0 or
QCmin = 0). Such designs are not separated at the pinch, and
are called Threshold Problems
Example - Consider the problem
CP
o
300o 200
H1 1.5
300o 250o
H2 2.0
200o 30o
C1 1.2

24 Advanced HEN Synthesis -7

 Threshold Problems (Contd)
Eliminate infeasible
Assuming a value of QHH
Assume
QHH = 0
(negative) heat transfer
QH = 6
Tmin= 105
10 oC,
oC:the 290ooC
T11 = 200
Problem Table gives H = -6
175
the following result. Q11 175 0
-6
oo
T22 = 195
240 C

H = 115
60

Q22 235
109 115
oo
T33 = 145
200 C

H = 15
3

Q33 238
124 130
oo
T44 = 95
190CC

H = -78
-192

QCC 46 52
oo
T55 = 30 C

QHMin Q
= HMin
0 kW= 6 kW Cold pinch temperature
Q 46 kW52 kW
QCMin = CMin = 195 oC
25 Advanced HEN Synthesis -7
 Threshold Problems (Contd)

Threshold problems do not have a pinch, and have non-zero

utility duties only at one end.

26 Advanced HEN Synthesis -7

 Threshold Problems (Contd)

Steam
T
Utility
Heat Loads

TT o
=o20o
= 10
T = 14o Cooling Water

Steam Tmin
CW
CW
CW
H 14o

However, increasing driving forces beyond the Threshold Value

leads to additional utility requirements.

27 Advanced HEN Synthesis -7

 Threshold Design Guidelines
1. Establish the threshold Tmin
2. Note the common practice values for Tmin:
Application Refrigeration Process Boiler
Tmin, Experience 1-2 oC 10 oC 20-30 oC

3. Compare the threshold Tmin to Tmin,Experience

Classify as one of the following:
Utilities Utilities

Tmin Tmin

Tmin,Experience Tmin,Experience
Pinched - treat as normal Threshold - must satisfy target
pinched problem temperatures at the no utility end

28 Advanced HEN Synthesis -7

 Class Exercise 6
The graph shows the effect of Tmin on the required levels
of QHmin and QCmin for a process consisting of 3 hot and 4
cold streams.

Q (104 Btu/h)

Hot Utility
QHmin

217.5
Cold Utility
QCmin

50 o Tmin, oF

29 Advanced HEN Synthesis -7

 Class Exercise 6 (Contd)
Design a network for Umin and MER for the process.
Hint: Identify two essential matches by satisfying target
temperatures oat the no utility end o
CP
590 400
H1 2.376

471o 200o
1.577
H2
533o 150o
1.32
H3
400o 200o
C1 1.6
430o 100o
C2 1.6
400o 300o
C3 4.128

280o 150o
C4 2.624
QHmin = 217.5 QCmin = 0

30 Advanced HEN Synthesis -7

 Class Exercise 6 - Solution
CP
o o o
590 573.7 400
2.376
H1
471o 416.3o o
416.3 200o
1.577
H2
533o 150o
1.32
H3
400o 200o
H C1 1.6
430o 195.1 38.7 86.3 416o 100o
H C2 1.6
400o 22.4 505.6 300o

C3 4.128
412.8 150o
280o
C4 2.624
QHmin = 217.5 341.1 QCmin = 0
Note: UMin = NStreams + NUtilities 1 = 7

31 Advanced HEN Synthesis -7

 Advanced HEN Synthesis - Summary

Loops and Splits

Minimum Number of Units by Loop Breaking -
Umin
Stream Split Designs - Umin and MER
Threshold Problems
Problems with only hot or cold utilities (no
pinch!)

32 Advanced HEN Synthesis -7