HEAT INTEGRATION:

Department of
Chemical Engineering
University of Engineering
And Technology, Lahore

A.N.Tabish
2009-MS-Chem-25

HEAT
INTEGRATION
HEAT
EXCHANGER
NETWORK
DESIGN

INTRODUCTION:

HEAT
INTEGRATION

A cold process stream can be heated by using steam or any hot utility,
available at a temperature higher than the target temperature of process
stream and a hot process stream can be cold by using cooling water or any
cold utility, available at a temperature lower than the target temperature of
process stream.
Situation refers the maximum use of utility that is merely an operating
cost, and maximum annualized cost that demands a larger rate of return to
make the process profitable.
A cold process stream can be used to lower the temperature of hot
process stream, which heats up the cold stream as well. Hence minimizing
the use of utility and ultimately operating cost and total annualized cost.
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Heat Integration, enables the maximum heat exchange between

process streams using Pinch Technology, that revealed various
methods to maximize process-to-process heat exchange and

minimized the use of utilities through an integrated network of

heat exchangers.
Application of Pinch analysis minimizes the energy
consumption

of

chemical

processes

by

calculating

thermodynamically feasible energy targets and achieving them

by optimizing heat recovery systems, energy supply methods
and process operating conditions. It is also known as process
integration, heat integration, energy integration or pinch
technology.
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Improvement in the energy consumption obtained

after successive designs of given product.

PROFITABILITY OPTIMIZATION:

Design for Minimum Capital Cost

Design for Minimum Energy Cost

Optimum Design for Minimum Energy Cost

Simple process flow sheet

Heat integrated flow sheet

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PINCH TECHNOLOGY:
1. Data Extraction: To formulate the
process flow sheet and perform
heat and mass balance.
2. Minimum Approach Temperature:
To select the minimum temperature
difference that can be allowed
across any heat exchanger in the
network.
3. Composite Curves: To draw the
enthalpy vs. temperature graph for
cold streams as well as for hot
streams
4. Minimum utility targets: To
calculate the minimum heating and
cooling requirements that must be
supplied by utility system.
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5. Heat Exchanger Network

(HEN) Design: To design a
network of heat exchangers to
exchange the energy between
process and utility streams.
6. Network Relaxation and
Optimization: To modify the
network to eliminate the small
exchangers which are not cost
effective.
7. Process Change: To alter the
process conditions of unit
operations and other streams
to maximize heat integration.

DATA EXTRACTION:

1. Process Flowsheet
2. Operating Conditions for process streams & unit operations
3. Heat and mass balance
4. Hot and cold stream allocation

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MINIMUM APPROACH TEMPERATURE (Tmin):

Area and cost variation with TLM

COMPOSITE CURVES:

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The hot streams plotted

separately

The composite hot stream

The cold streams plotted separately

The composite cold stream

MINIMUM UTILITY TARGET:

For an efficient network synthesis it is required to evaluate MAXIMUM
ENERGY RECOVERY (MER) so that MINIMUM UTILITY TARGET can be
selected and network may be designed so as to satisfy the energy
requirements for each process stream that is the determination of
minimum hot and cold utility requirements in the process.
Three methods are widely used for the estimation of minimum utility
requirement.
1.
2.
3.

Graphical method
Algebraic method
Computer based methods

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MINIMUM UTILITY TARGET: (Graphical Method)

Production of Maleic Anhydride from Benzene

HEAT EXCHANGE STREAM DATA

Stream

Supply
Temperature
(oC)

Streams to be heated
2
30
4
117
17
34
28
105
Streams to be cooled
8
400
11
76.3
Salt
360
32
136
36
202

Target
Temperature
(oC)

Enthalpy
Change rate
(kJ/sec)

110
380
95
161

399
5270
310
253

76.3
60
340
30
30

-7170
-450
-7667
-154
-558

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INITIAL TEMPERATURE INTERVAL TABLE

Source
Enthalpy
Target
Stream
Temperature
Change rate
o
Temperature
(
C)
(oC)
(kJ/sec)
Streams to be Heated: (for enthalpy baseline value of 11000 kJ/sec)
2
30
34
5
2 &17
34
95
397
2
95
105
310
2 & 28
105
110
35
28
110
117
50
5 & 28
117
161
1025
5
161
380
4410
Total = 6232

Initial Enthalpy Selection

Enthalpy
11000
11005
11402
11712
11747
11797
12822
17232

Temp
30
34
95
105
110
117
161
380

17000
16106
7988
4968
3178
1533
1053
1000

400
360
340
202
136
76
60
30

Streams to be cooled: (for enthalpy baseline value of 17000 kJ/sec)

8
8 & salt
8
8 & 36
8, 36 & 32
11, 36 & 32
36 & 32

400
360
340
202
136
76
60

360
-894
340
-8118
202
-3020
136
-1790
76
-1645
60
-480
30
-53
Total = -16000

Initial composite diagram with Tmin = 28 oC

Hot stream pinch Temperature = 358 oC
Cold stream pinch Temperature = 330 oC.
So,
Tmin at pinch point is 28 oC.

While allowable Tmin for chemical processes is 3 - 10 oC.

Revision of temperature interval table

Slop of the curve at pinch point = 0.0475
Intercept of the curve = - 440
For

y = mx + c
Modified enthalpy change rate at 358 oC is 16800 kJ/sec.

This value of 16800 must be increased to 17000 to make the

temperature approach at the pinch point to 10oC. Therefore 200 kJ/hr
must be added to every enthalpy change rate value associated with
the streams to be heated. Hence, Difference of baseline enthalpy
change rates = 200 kJ/sec
So, Revised baseline enthalpy change rate for streams to be
cooled = 17200 kJ/sec.
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Revised temperature interval table

Stream

Source
Temperature
(oC)

Streams to be Heated:
2
2 &17
2
2 & 28
28
5 & 28
5

30
34
95
105
110
117
161

Target
Temperature (oC)

Enthalpy
Change rate
(kJ/sec)

34
95
105
110
117
161
380

Initial Enthalpy Selection

5
397
310
35
50
1025
4410

Enthalpy
11000
11005
11402
11712
11747
11797
12822
17232

Temp
30
34
95
105
110
117
161
380

-894
-8118
-3020
-1790
-1645
-480
-53

17200
16306
8188
5168
3378
1733
1253

400
360
340
202
136
76
60

1200

30

Total = 6232
Streams to be cooled:
8
8 & salt
8
8 & 36
8, 36 & 32
11, 36 & 32
36 & 32

400
360
340
202
136
76
60

360
340
202
136
76
60
30

Total = -16000

Revised composite diagram

with Tmin = 10 oC

Revised composite diagram

with Tmin = 10 oC

Minimum heating utility required = 17232 17200 = 32 kJ/sec

Minimum cooling utility required = 11000 1200 = 9800 kJ/sec
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MINIMUM UTILITY TARGET: (Algebraic Method)

Algebraic method is also termed as Problem Table Method.

Although composite curves can be used to set energy targets, yet
they are inconvenient because they are based on a graphical
construction. The problem table is the name given by Linnhoff and
Flower to a numerical method for determining the pinch temperatures
and the minimum utility requirements; Linnhoff and Flower (1978)
also termed as Temperature Interval Method. Once understood,
it is the preferred method, avoiding the need to draw the composite
curves.

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Hot stream Temperature:

Cold stream Temperature:

Shifted temperatures for data:

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Shifted temperatures for data:

The temperature interval heat balance:

HEAT EXCHANGER NETWORK DESIGN:

HEAT EXCHANGER
NETWORK DESIGN

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PROBLEM STATEMENT:
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 are the heat capacity of each process hot streams,
FCP,u; its supply (inlet) temperature, Ts,u; and its target (outlet)
temperature, Tt,u, where u = 1, 2 ,., NH.
Given also are the heat capacity of each process cold streams,
FCP,v; its supply (inlet) temperature, Ts,v; and its target (outlet)
temperature, Tt,v, 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.

CAPITAL AND ENERGY COSTS:

Heat exchanger network that would
seem appropriate to most when energy
is cheap and capital expensive.

Heat exchanger network that would

seem appropriate to most when energy
is expensive and capital cheap.

CAPITAL AND ENERGY COSTS Contd..:

Capital Cost = f(Thermodynamic effects)

= f(Driving forces, Heat loads)
Evidently, as we go to tighter designs (i.e. to reduce driving forces) we need less
utility and the overall heat load decreases. Capital cost then increases with reduced
driving forces (we all know that) but decreases with reduced heat load (we rarely
consider this point).

CAPITAL AND ENERGY COSTS Contd..:

HEAT EXCHANGER NETWORK DESIGN:

The process streams are drawn as horizontal lines, with the stream numbers
shown in square boxes. The Hot streams are drawn at the top of the grid, and flow
from left to right. The cold streams are drawn at the bottom, and flow from right to
left. The stream heat capacities CP are shown in a column at the end of the stream
lines. Heat exchangers are drawn as two circles connected by a vertical line. The
circles connect the two streams between which heat is being exchanged; that is, the
streams that would flow through the actual exchanger. Heater and coolers are drawn
as a single circle, connected to the appropriate utility.

THE PINCH DESIGN METHOD:

If the energy target set by the composite curves is to be achieved, the
design must not transfer heat across the pinch by:
1.
2.

Process-to-process heat transfer

Inappropriate use of utilities

QCmin

QHmin

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THE PINCH DESIGN METHOD Contd..:

Stream matching is started at the pinch point to avoid the violation of

the assumption of Tmin.
If such matches are not made, the result will be either use of temperature
differences smaller than Tmin or excessive use of utilities resulting
from heat transfer across the pinch.
If the design is started away from the pinch at the hot end or cold end of
the problem, then initial matches are likely to need follow-up matches
that violate the pinch or the Tmin criterion as the pinch is approached.
If the design is started at the pinch, then initial decisions are made in
the most constrained part of the problem. This is much less likely to
lead to difficulties later.
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THE PINCH DESIGN METHOD Contd..:

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THE PINCH DESIGN METHOD Contd..:

THE PINCH DESIGN METHOD Contd..:

THE PINCH DESIGN METHOD Contd..:

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THE PINCH DESIGN METHOD Contd..:

At the pinch, the match starts with a temperature difference

equal to Tmin. The relative slopes of the temperatureenthalpy
profiles of the two streams mean that the temperature
differences become smaller moving away from the pinch, which
is infeasible. On the other hand, in second Figure match
involving the same hot stream but with a cold stream that has a
larger CP. The relative slopes of the temperatureenthalpy
profiles now cause the temperature differences to become larger
moving away from the pinch, which is feasible.
Thus, starting with Tmin at the pinch, for temperature
differences to increase moving away from the pinch.
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THE PINCH DESIGN METHOD Contd..:

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THE PINCH DESIGN METHOD Contd..:

If a cold stream is matched with a hot stream with smaller CP,

(i.e. a steeper slope), then the temperature differences become
smaller (which is infeasible). If the same cold stream is matched
with a hot stream with a larger CP (i.e. a less steep slope), then
temperature differences become larger, which is feasible.
Thus, starting with Tmin at the pinch, for temperature
differences to increase moving away from the pinch.

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THE PINCH DESIGN METHOD Contd..:

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THE PINCH DESIGN METHOD Contd..:

THE PINCH DESIGN METHOD Contd..:

NUNITS S 1

NUNITS ( S 1)

ABOVE THE PINCH

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( S 1)

BELOW THE PINCH

THE PINCH DESIGN METHOD Contd..:

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THE PINCH DESIGN METHOD Contd..:

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