HEAT INTEGRATION Analysis 7.

Cost estimation

Heat Integration UVa | Analysis

07. Cost estimation 1

Outline
Heat exchanger network cost structure Assessing HEN cost Minimum number of units Minimum exchange area Special Heat Exchangers Calculating total costs Optimizing minimum temperature difference Summarizing Pinch Analysis

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07. Cost estimation 2

Heat exchanger network cost structure

Process (mainly fixed costs):
prime matters personnel expenses fixed assets (mainly equipment investment)

HEN:
operating costs (mainly energy)
utility flows utility type and level pumping costs across HX

fixed assets
number of HX (units) Heat exchange area HX nature: materials/pressure

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07. Cost estimation 3

Assessing HEN cost

In order to choose among alternatives (design/retrofit of a new HEN) General approach:
avoid detailed design seek minimums

Energy operating costs

minimum heating and cooling T level / type of utility

Fixed assets
Minimum number of HX Minimum heat exchange area Materials/pressure: as enhanced area

Minimum temperature difference: critical parameter Results: surprisingly accurate in practice

Heat Integration UVa | Analysis 07. Cost estimation 4

Minimum number of units

Build balanced composite curves for:
a concrete Tmin specific utilities / utility streams

Locate the pinch (hot Tpinch / cold Tpinch) Count stream number (including utilities) above (NA) and below (NB) the pinch From Graph theory: Nmin= [NA-1] + [NB-1] [insight: each contact solve the needs of one -smallest onestream, and the last contact of the two (balanced)]
Heat Integration UVa | Analysis 07. Cost estimation 5

Minimum exchange area

Bath algorithm (from a Heat Integration symposium at Bath, UK)

Build balanced composite curves (including utility streams) Divide the diagram into enthalpy intervals at slope changes of either curve

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07. Cost estimation 6

Minimum exchange area

Take each interval for a conceptual counter-current heat exchanger whose area:
Ak = H Uk T ln k

And, for the network as a whole:

Intvls

A HEN =

1 Ak = U

Intvls

abs H T ln k

Normally Uk is not the same for every stream, an then:

Intvls

A HEN =

1 T ln k

Streams

abs qi hi

]]
07. Cost estimation 7

Where qi is the duty contribution of stream i to the interval

Heat Integration UVa | Analysis

Minimum exchange area

Accuracy: normally better than 10% for counter-current HX provided that the maximum difference between heat transfer coefficients is less than an order of magnitude (otherwise: linear optimization) Real area < minimum area (complex networks, small HX)

Countercurrent heat exchangers can lend a good cost estimation, but for 1:2 HENS
Intvls

AHEN =

1 T ln k F Tk

Streams

abs qi hi

[Linnhoff, Ahmad 'Cost optimum heat exchangers networks: I. Minimum energy and
capital using simple models for capital cost' Computers Chem. Eng. 14; 729, 1990]

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07. Cost estimation 8

Special Heat Exchangers

If all heat exchangers follow the same law of cost
Cost = a b A c ,, Cost HEN = N min

[ ]
A HEN ab N min
c

Some heat exchangers can be different:

Building material (Corrrosive streams, legislation) Type / heat exchange technology Pressure difference between streams

To take this into account HEN area is increased using a correction factor for the special heat exchanger
Intvls

AHEN =

1 T ln k

Streams

abs qi i hi

]]
07. Cost estimation 9

Heat Integration UVa | Analysis

Special Heat Exchangers

Correction factor calculation:
Choose the most abundant type of HX as the reference HX Cost REF = a REF b REF A REF Special HX cost law is modified in order to
a SPC = a REF ,, Cost SPC = a REF b SPC A
cSPC c

Correction factor is calculated as:

SPC =

[ ] [ ]
b REF
c REF

A HEN N min

c spc cREF

b SPC

of course REF = 1

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07. Cost estimation 10

Calculating total costs

Tmin

Composite curves Pinch Minimum Heating&Cooling Cost Laws Annual Utility cost Total annual cost
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Nmin , AHEN Cost Laws Fixed assets Annualization Annual Equipment cost

07. Cost estimation 11

Optimizing minimum temperature difference

Minimum temperature difference is a critical parameter
Not strictly a physical temperature difference in a concrete HX More an abstract indicator of the tightness of the network Fix a compromise between energy and investment costs

Cost studies should be based on the optimization of Tmin :

T min 9 10 11 ------C qH 1425 1630 1850 ------kW qC 2600 2805 3025 ------kW CostENR 203458 206857 225698 ------/a NMIN 9 9 8 ------units A HEN 3512 3629 3870 ------m2 CostINV 72890 64350 52689 ------/a CostTOT 276348 271207 278387 ------/a

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07. Cost estimation 12

Optimizing minimum temperature difference

Variation patterns of design/costing variables:

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07. Cost estimation 13

Optimizing minimum temperature difference

Combining energy and investment costs:

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07. Cost estimation 14

Summarizing Pinch Analysis

We can:
Estimate operating (energy) cost
Calculate utility requirements Calculate utility level/type

Estimate fixed assets (investment)

Calculate minimum number of heat exchangers Calculate minimum HEN area (including normal+special HX)

Estimate total costs

Annualizing and combining energy and investment costs

This allows us to:

Select alternatives on economic criteria Get reliable estimates of the final costs Determine values of critical design variables

... Without detailed design

Heat Integration UVa | Analysis 07. Cost estimation 15