CDB 4313 HEAT INTEGRATION

BASIC HEAT INTEGRATION

ZULFAN ADI PUTRA, PDENG

OFFICE: 05-03-08
TELP: 05 368 7562
EMAIL: Zulfan.adiputra@utp.edu.my
Discussion time: Friday 15.00 17.00
COURSE OVERVIEW
Data extraction
Composite Curve
Problem Table Algorithm
Grand Composite Curve
Basics Placement of utilities
Process Modification (+/-)
Heat Exchanger Network Design

HEAT Capital Cost Targeting

INTEGRATION
Retrofitting of
Heat Exchanger Network
Process
integration Reactors and separators

Heat engines and heat pumps

LP/MILP
Automated design
MINLP
2
COURSE LEARNING OUTCOMES
At the end of this course, students shall be able to:

1. Perform targeting exercise to determine the minimum utility requirements

and maximum heat recovery possible for a process using composite curve or
problem table algorithm

2. Design heat exchanger network for achieving maximum energy recovery or

minimum total cost using pinch analysis technique

3. Apply pinch analysis software to perform heat integration and heat

exchanger network design that is cost competitive and taking into account of
sustainability factors

4. Analyze the potential for heat and power integration of a process and the
possible implementation options, and to screen the options using cost
effective strategy

5. Perform correct data extraction from process flowsheet for the purpose of
performing pinch analysis

3
INTRODUCTION

Onion diagram for process synthesis

Pinch Analysis setting energy targets based on thermodynamics, prior to design

Appropriate changes can be identified to minimize energy consumption

4
STEPS IN PINCH ANALYSIS
Identify
hot and cold streams

Tmin

Construct
Composite Curves &
Grand Composite Curve

Estimate minimum energy targets Select another Tmin

Identify appropriate
process modification

Integrate other process equipment

Estimate heat exchanger network

capital target and total cost

Select optimum Tmin Tmin

Design heat exchanger network

5
HEAT EXCHANGING
10 kg/hr 10 kg/hr
100 oC 80 oC
4 kJ/kgK Q 4 kJ/kgK

kg/hr 5 kg/hr
oC 30 oC
kJ/kgK 3 kJ/kgK

Temperature
(oC)

Q
Q = mcpT

Enthalpy
(kW)
6
DATA EXTRACTION (1)

COND Stream 2
COND H = 330 kW
20O C 170O C
20O C CP = 3 kW/oC
170O C

R2
60O C R2
H = 230 kW 60O C
C1
H = 100 kW C1 Stream 1
H = 230 kW
R1 CP = 2 kW/oC
R1
REB 135O C REB
135O C
150O C
140O C 150O C
H = 150 kW
140O C
102.5O C Stream 4
30O C H = 180 kW Stream 3
90O C CP = 1.5 kW/oC H = 240 kW
H = 90 kW 30O C CP = 4 kW/oC
H = 90 kW
80O C 80O C

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DATA EXTRACTION (2)
Extracted Data
Stream 2 Stream Type Temp. Temp. Load Flow
COND H = 330 kW supply (oC) req. (oC) (kW) (kW/oC)
20O C CP = 3 kW/oC
170O C 1 Cold 20 135 230 2

R2 2 Hot 170 60 330 3

60O C
C1 Stream 1 3 Cold 80 140 240 4
H = 230 kW
CP = 2 kW/oC
R1 4 Hot 150 30 180 1.5
REB
135O C
150O C

140O C
Stream 4
H = 180 kW Stream 3
CP = 1.5 kW/oC H = 240 kW
30O C CP = 4 kW/oC
80O C

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DATA EXTRACTION (3)
Data extraction rules:
- Linearize data on the safe side

- Do not mix streams

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DATA EXTRACTION (4)
- Do not extract utilities (it is to be designed!)
- Extract at effective temperature

- For soft data, check if hot/cold utilities can be reduced via composite curve
Why? Why not?

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COMPOSITE CURVE: COLD COMPOSITE CURVE

Temperature (oC) Temperature (oC)

140 140
135 135
3 3
80 80
1 1

20 20

230 470 120 450 470

110+220

Enthalpy (kW) Enthalpy (kW)

(a) (b)

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COMPOSITE CURVE: HOT COMPOSITE CURVE

Temperature (oC) Temperature (oC)

170 170

150 150
2

60 60
4

30 30

330 510 45 450 510

135+270
Enthalpy (kW) Enthalpy (kW)
(a) (b)

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COMPOSITE CURVE

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COMPOSITE CURVE WITH DIFFERENT TMIN

Tmin = 10 oC Tmin = 20 oC

Tmin = 30 oC Tmin = 40 oC

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PROBLEM TABLE ALGORITHM (ADJ. TEMP.)
Adjusted temperature with T = 20 oC,
Original data
THOT = THOT-0.5 T, TCOLD = TCOLD+0.5 T
Stream Temp. Temp. Flow Stream Temp. Temp. Flow
supply (oC) req. (oC) (kW/oC) supply (oC) req. (oC) (kW/oC)
1 20 135 2 1 30 145 2

2 170 60 3 2 160 50 3

3 80 140 4 3 90 150 4

4 150 30 1.5 4 140 20 1.5

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PROBLEM TABLE ALGORITHM (ADJ. TEMP.)

Shift
Interval T(i+1)-Ti mCpnet dH
Temperature
C C kW/K kW
160
1 10 3.0 30.0 surplus
150
2 5 -1.0 -5.0 demand
145
3 5 -3.0 -15.0 demand
140
4 50 -1.5 -75.0 demand
90 PIN
5 40 2.5 100.0 surplus
50
6 20 -0.5 -10.0 demand
30
7 10 1.5 15.0 surplus
20

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PROBLEM TABLE ALGORITHM (ADJ. TEMP.)

Shift
Interval T(i+1)-Ti mCpnet dH
Temperature Infeasible Cascade Feasible Cascade
C C kW/K kW
160 0 65
1 10 3.0 30.0 surplus 30 30
150 30 95
2 5 -1.0 -5.0 demand -5 -5
145 25 90
3 5 -3.0 -15.0 demand -15 -15
140 10 75
4 50 -1.5 -75.0 demand -75 -75
90 PINCH -65 0
5 40 2.5 100.0 surplus 100 100
50 35 100
6 20 -0.5 -10.0 demand -10 -10
30 25 90
7 10 1.5 15.0 surplus 15 15
20 40 105

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COMPOSITE CURVE (WITH ADJUSTED TEMPERATURE)

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GRAND COMPOSITE CURVE (GCC)

Shift Shift
Interval T(i+1)-Ti mCpnet dH Interval T(i+1)-Ti
Temperature Infeasible Cascade
Temperature Feasible Cascade
C C kW/K kW C C
160 0 160 65
1 10 3.0 30.0 surplus 30 1 30 10
150 30 150 95
2 5 -1.0 -5.0 demand -5 2 -5 5
145 25 145 90
3 5 -3.0 -15.0 demand -15 3 -15 5
140 10 140 75
4 50 -1.5 -75.0 demand -75 4 -75 50
90 PINCH -65 90 0
5 40 2.5 100.0 surplus 100 5 100 40
50 35 50 100
6 20 -0.5 -10.0 demand -10 6 -10 20
30 25 30 90
7 10 1.5 15.0 surplus 15 7 15 10
20 40 20 105

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UTILITY PLACEMENT (VARIOUS OPTIONS)

1 1: Steam at 170 oC, 65 kW

CH 5 80 oC, 105 kW

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UTILITY PLACEMENT (VARIOUS OPTIONS)

1 1: Steam at 170 oC, 65 kW

CH 5 15 oC, 105 kW

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UTILITY PLACEMENT (VARIOUS OPTIONS)

2
2: Steam at 150 oC, 65 kW

CW 30 80 oC, 90 kW
CH 5 15 oC, 15 kW

22
UTILITY PLACEMENT (VARIOUS OPTIONS)

3
3: Steam at 150 oC, 25 kW,
steam at 120 oC, 40 kW

Hot water producer, 60 90 oC, 40 kW

CW 30 40 oC, 50 kW
CH 5 15 oC, 15 kW

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COURSE OVERVIEW
Data extraction
Composite Curve
Problem Table Algorithm
Grand Composite Curve
Basics Placement of utilities
Process Modification (+/-)
Heat Exchanger Network Design

HEAT Capital Cost Targeting

INTEGRATION
Retrofitting of
Heat Exchanger Network
Process
integration Reactors and separators

Heat engines and heat pumps

LP/MILP
Automated design
MINLP
24
QUESTIONS?

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