Heuristics

Heat
for Integration
Process Synthesis

CHME 466 Process Integration

Dr. Saad Ali Al-Sobhi

Department of Chemical Engineering
Qatar University

Chapter 9 Heat Integration

Sep 23,2017

Contains some Materials Prepared by Dr. Mahmoud El-Halwagi

1
 Announcements

First week materials already posted on BB

Home work no. 1 is due Sunday (1st Oct
2017)
Make sure to pick up your book
 Chapter 9 Topic Coverage
Define Heat Integration Problem Statement
Questions that heat integration methods
address
Pinch Tools and Fundamentals
Pinch Diagram Construction & Analysis
Algebraic Pinch Analysis
Grand Composite Curve (GCC)
Pinch Diagram Analysis & Screening of
Utilities
 Problem Statement 1
Given a number NH of process hot streams (to be cooled)
and a number NC of process cold streams (to be heated),
it is desired to synthesize a cost-effective network of heat exchangers
that can transfer heat from the hot streams to the cold streams.

Given also the heat capacity (flowrate x specific heat)

of each process hot stream, FCP,u ; its supply (inlet) temperature, Tus;
and its target (outlet) temperature, Tut, where u = 1,2,...,NH.

In addition, the heat capacity, fcP,v , supply and target temperatures,

tvs and tvt are given for each process cold stream, where v = 1,2,.,NC.
Available for service are NHU heating utilities and NCU cooling utilities
whose supply and target temperatures (but not flowrates) are known.
 Problem
Objectives
Statement 2

Given data on the hot and cold streams of a process, you

should be able to:

Compute the pinch temperatures

Identify minimum heating/cooling utility targets using

graphical and/or algebraic methods

Design the network of heat exchangers that satisfy

utility targets
 Cold Streams In

Heat
Hot Hot
Streams
Exchange Streams
In Network Out
(HEN)

Cold Streams Out

Which heating/cooling utilities should be employed ?

What is the optimal heat load to be removed/added by each utility?
How should the hot and cold streams be matched (i.e., stream
pairings)?
What is the optimal system configuration (e.g., how should the heat
exchangers be arranged? Is there any stream splitting and mixing ?)
 HEN
First, determine minimum energy
requirement (MER) targets by three
methods
(1) the temperature interval (TI) method
(2) graphical approach
(3) formulation and solution of a linear program (LP)
Second, design the network to meet MER
targets by two methods
(1) unit by unit method
(2) formulation and solution of mixed integer linear program
(MILP)
 Some Definitions 1:2

Temperature scales
Hot stream temperatures (T) Cold
Streams In
Cold stream temperatures (t)

Thermal equilibrium Hot Heat Hot

Achieved when T = t Streams Exchange Streams
In Network Out
(HEN)
Inclusion of temperature
driving force Tmin Cold
T = t + Tmin Streams Out

Thus substracting Tmin from

the hot temperatures will
ensure thermal feasibility at
all times
Practical Feasibility of Heat Transfer

Thermal equilibrium: T = t
Practically-feasible heat transfer: T = t + T
Annualized
Cost, $/yr

The selection of Tmin

Total
Annualized is a key design for HEN
T min
Cost Also, it sets the amount
of heat recovery
Annual
Minimum Total Operating
Annualized Cost
Cost

Annualized
Minimum Annual
Operating Cost
Fixed
Cost

0 T opt T m in
T min
Trading off Fixed vs. Operating Cost
 HENs

HENs
Transferred commodity: Heat

Donors: Hot streams

Recipient: Cold streams
Hot temperature: T
Cold temperature: t
Slope of equilibrium: 1
Intercept of equilibrium: 0
Driving force: Tmin
Constructing the Hot Composite Stream (Big Picture for Hot Streams)
Heat lost from the u-th hot stream HHu = FuCp,u(Tus-Tut)
Heat
Exchanged

H2
HH2

HH1 H1
t t s s T
T 1 T 2 T 1 T 2
Using Superposition to Construct the Hot Composite Stream

We create a hot composite stream

using the diagonal rule for overlapped
regions of streams
 Constructing the Cold Composite Stream (Big Picture for Cold Streams)
Heat
Exchanged
Heat gained by the v-th cold stream HCv = f v c p,v (tvt tvs )

HC2 C2

HC1 C1
T
t T T
s min
ts
1
t 2
t
t
1 t t
2
Using Superposition to Construct the Cold Composite Stream
Heat
Exchanged

Cold
HC2 Composite
Curve

HC1
T
t T Tmin
s
ts
1
t 2
t
t
1 t t
2
Heat
Exchanged Cold
Composite
Stream

Hot
Composite
Stream

T
t T T min
Heat Thermal Pinch Diagram
Exchanged

Heat Exchange Minimum

Pinch Point Heating Utility

Cold Hot Maximum

Composite Composite Integrated
Heat
Stream Stream
Minimum Exchange
Cooling
Utility
T
t T T min
 Too much integration

Cold
Composite
Stream
Infeasibility
Region Hot
Composite
Stream

T
t T T min
 Too little integration: Passing heat through the pinch
Heat
Exchanged

Minimum
Heating Utility
Cold
Composite
Maximum
Stream
Hot
Composite Integrated
Heat
Stream
Exchange
Minimum
Cooling
Utility T
t T Tmin
 Thermal Pinch Analysis

Optimum design rules for thermal pinch analysis

No heat should be passed through the pinch
Above the pinch, no cooling utilities should
be used
Below the pinch, no heating utilities should
be used.
 Significance of the pinch

It divides the system into two distinct

thermodynamic regions
The region above the pinch can be
considered as a heat sink, i.e., heat flowing
into it from the hot utility but not out of it
Below the pinch heat flows out of the
region to the cold utility
 Threshold problem
Problems that show the characteristic of requiring
either a hot utility or a cold utility but not both
over a range of minimum temperature difference
from zero up to a threshold value
Can be treated as one half of a problem exhibiting
a pinch
The design of threshold problems is discussed by
smith (1995) and IchemE (1994)
 HEN
First, determine minimum energy
requirement (MER) targets by three
methods
(1) the temperature interval (TI) method
(2) graphical approach
(3) formulation and solution of a linear program (LP)
Second, design the network to meet MER
targets by two methods
(1) unit by unit method
(2) formulation and solution of mixed integer linear program
(MILP)
Example Revisited
Solvent

H1
460 K 350 K Offgas
Scrubber
(to gas treatment)

Spent Solvent
C1 (to regeneration)
Feed
Reactor I 420 K 490 K Reactor II Byproducts

H2
400 K 300 K Product
Separation (to sales)
Network

C2
320 K 390 K Flash
Column

Wastewater
Chemical Process Stream Data

Flowrate x Cpu T us T ut HHu

Stream kW/K K K kW
H1 300 460 350 33,000
H2 500 400 300 50,000
C1 600 420 490 42,000
C2 200 320 390 14,000

Current Usage of Cooling Utility: 83,000 kW

Current Usage of Heating Utility: 56,000 kW
 HEN Algebraic Approach

Construct a Temperature Interval Diagram (TID)

Generate Table of Exchangeable Heat Loads

(TEHL) for cold & hot streams

Cascade diagram representation

 Temperature Interval Diagram

Hot Streams Cold Streams

Interval T t
500 490

f1Cp1 = 600
1 H1 460 450

2
F1Cp1 = 300

430 420
C1
3 H2 400 390
4
F2Cp2 = 500

350 340

= 200
f2Cp2
5
330 320
6
C2
300 290
 TEHL Hot Streams

Exchangeable load of the uth hot stream passing

through the zth temperature interval:
HH u ,z Fu C p ,u Tz 1 Tz

Load of H1 Load of H2 Total Load

Interval (kW) (kW) (kW)
1 - - -
2 9,000 - 9,000
3 9,000 - 9,000
4 15,000 25,000 40,000
5 - 10,000 10,000
6 - 15,000 15,000
 TEHL Cold Streams

Exchangeable capacity of the vth cold stream

passing through the zth temperature interval:
HCv ,z f vC p ,v Tz 1 Tz

Capacity of C1 Capacity of C2 Total capacity

Interval (kW) (kW) (kW)

1 24,000 - 24,000
2 18,000 - 18,000
3 - - -
4 - 10,000 10,000
5 - 4,000 4,000
6 - - -
 Cascade Diagrams

Heat balance around each temperature interval:

rz HH zTotal HC zTotal rz 1

Residual heat from

preceding interval

rz 1
HzzH Hz z
Total CTotal
HH HC
Heat added by
hot streams z Heat removed
by cold streams

rz
Residual heat to
subsequent interval
Cascade Diagrams
Original rz HH zTotal HC zTotal rz 1
Revised
of H1 33Load
min
Q
Load
Heating ,000ofkW
H2 Total Load
0 Interval (kW) (kW) (kW)
0 24,000 1 0 - - 24,000 -
1 1
2 9,000 - 9,000
-24,000 9,000
9,000 18,000 3 9,000 9,000 - 18,000 9,000
2 4 15,000 2 25,000 40,000
-33,000 5 - Thermal-Pinch
0 10,000 Location
10,000
9,000 0 9,000 0
33 6 - 33 15,000 15,000
-24,000 9,000
Capacity of C1 Capacity of C2 Total capacity
40,000 10,000 Interval 40,000(kW) (kW) 10,000 (kW)
4 4

6,000 1 24,000 -
39,000 24,000

10,000 4,000 2 18,000

10,000 - 4,000 18,000
5 5
3 - - -
12,000 4 - 45,000
10,000 10,000
15,000 0 5 15,000 - 4,000 0 4,000
6 6
6 - - -
27,000
min
QCooling 60,000 kW
 Savings in utilities

83,000 60,000
Target for percentage savings in cooling utility = *100% 28%
83,000

56,000 33,000
Target for percentage savings in heating utility = *100% 41%
56,000
 First, determine minimum energy
requirement (MER) targets by three
methods
(1) the temperature interval (TI) method
(2) graphical approach
(3) formulation and solution of a linear program (LP)
Second, design the network to meet MER
targets by two methods
(1) unit by unit method
(2) formulation and solution of mixed integer linear program
(MILP)
General Hot Composite Curve

150,000

120,000
Heat Exchanged, kW

90,000 Hot Composite

83,000
Curve
60,000
50,000

30,000

0
350 400 460
300 330 360 390 420 450 480 510 T, K
General Cold Composite Curve

150,000

120,000
Heat Exchanged, kW

90,000

60,000
56000
Cold Composite
Curve
30,000

14,000

0
390 490
290 320 350 380 410420 440 470 500 t, K
 Thermal Pinch Diagram
Heat
Minimum
Exchanged, Utility
kW determined
Heat Exchange
120,000 Pinch Point
@ Topt = 10
116,000
min
QHeating
90,000 33,000kW
83,000
Cold Composite
56,000 33,000
Curvesavings in heating utility =
Target for percentage x100% 41%
56,000
60,000
Target for percentage savings in cooling utility = 83,000 60,000 x100% 28%
83,000
min
QCooling Hot Composite
60,000 kW Curve

0 ~385 ~445 500

300 330 360 390 420430 450 480 510 T, K

290 320 350 380 410420 440 470 500 t = T - 10, K

 HEN Graphical Approach

150,000
Heat
Exchanged
kW 120,000
116,000
min
QHeating
90,000 33,000kW
83,000

60,000

min
QCooling
60,000 kW

0
300 330 360 390 420 450 480 510 T, K

290 320 350 380 410 440 470 500 t = T - 10, K