Utilities and Utilities Targeting: Utilities For A Process

Lecture 6
Utilities and Utilities Targeting
L06 - 1 Design of Heat Exchanger Networks for Multiple Utilities Centre for Process Integration © 2010
Utilities for a process

BFW preheat
Boiler House and
Power Plant
Fuel HP
Steam
MP
Fuel
Steam
Steam W
Turbine
LP
Steam
Gas
W
Turbine
BFW
Preheat Q Q Q Q Q
Q+W
Flue Gas
Heat W
PROCESS Pump
Q
Q
Furnace Hot Oil

Q
Q Q
Air Preheat
Fuel Refrig - W
eration
Q+W
Cooling
Water
We normally have a choice of many hot and cold utilities.

Hot Utilities
• Steam HP, MP, LP
• Condensate
• Hot water
• Flue gas
• Gas turbine exhaust
• Hot oil
• Heat pump reject
Cold Utilities
• Cooling water
• Cooling air
• Air Preheat
• BFW preheat
• Heat pump heat sink
• Refrigeration
Hot Utilities: Generation and Use
We want to USE at the LOWEST level Lowest cost

and GENERATE at the HIGHEST level Highest cost
Cold Utilities: Generation and Use
We want to USE at the HIGHEST level Lowest cost

and GENERATE at the LOWEST level Highest cost
A Typical Steam System
Back -pressure
Turbines HP-Steam
IP-Steam
Boiler G
LP-Steam
Condenser
0.1 bara
Fuel 40 OC
C.W.
Condensing
Treated Water Turbine
Boiler Feedwater Treatment
VENT
Raw Water Boiler BFW Condensate Return
Make-up Feedwater LP Steam
Treatment
DEAERATOR
Chemical
Treatment
HP Steam
BOILERS
Fuel
Boiler Blowdown
Steam Use - Heat and Power
VENT
Raw Water Boiler BFW Condensate Return

Make-up Feedwater LP Steam
Treatment
DEAERATOR
Chemical Treatment Fuel
Emissions
Air
BOILERS Fuel W
Boiler Blowdown
HP STEAM
Condensing
Turbine
Process Vacuum
Back To Deaerator
Pressure
Turbines
CW
MP STEAM
Process
LP STEAM
Process
Furnace
High temperature heat required by processes is supplied
by combustion of fuels in a furnace
STACK
Finned Tubes
CONVECTION
SECTION Shield or Shock Tubes
RADIANT Radiant Section Tubes

SECTION Horizontally or Vertically
Mounted
BURNERS
Designs vary according to application
Furnace: flue gas
Furnace
T
TTFT TStack
QHmin
Fuel TTFT
TStack
Air
TO
Stack QH H
Loss
TTFT = Theoretical Flame Temperature
Hot Oil Circuits
T return
Process
T supply Duty
T Tsup
l
Oi
e ss
Tret Proc
Q H
What is the minimum hot oil flowrate ?
Refrigeration
Cooling Water
Expansion
valve
Level 1
Expansion
valve
W
Level 2
How do we target for the

best mix of utilities
➪ The Grand Composite Curve
The Problem Table
QHmin = 55
*
Tinterval
80
40
ZERO
⇐ PINCH
30
45
QCmin = 20
Let's plot this on a T - H diagram.

The Problem Table
QHmin = 55
T*
QHmin = 55
80 80
40 40
ZERO
30 30
45 45
QCmin = 20
QCmin = 20
∆H
Also Related to Composite Curves
T* T
QHmin = 55 QHmin = 55
80 80
∆Tmin
40 2 40
30 30
45 45 ∆Tmin
2
QCmin = 20
∆H QCmin = 20 ∆H
Heat Cascade
QHmin = 55 T*
Hot Utility Excess hot
streams
80
40
Excess cold
streams
ZERO
30
45
QCmin = 20 Cold Utility

∆H
The “Grand Composite Curve”
T*
QHmin
Excess hot
streams
Excess cold
streams
Pinch
'Pockets' of additional
heat recovery
QCmin
∆H
Heat Source and Heat Sink on GCC

T*
QHmin
Heat
Sink
Heat
Source
QCmin
∆H
The grand composite gives the hot and
cold utility requirements of the process
both in ENTHALPY AND TEMPERATURE
GCC and Utility Placement

Now place utilities.
T* T*
HP HP
MP
LP
∆H ∆H
Utility Pinch
NOTE:
Each time a utility profile touches the grand composite curve
T*
HP
MP
∆Tmin
LP
∆H
A new pinch (utility pinch) is created
Hot Oil Circuits
Treturn
Tin
Process
Tsupply Tout Duty
T
Tsup
Tret Tout
Tin
Q H
Capital Costs Energy Costs

Furnace Pumping
Pumps Furnace efficiency
Pipework
Normally : Maximise Tsupply
Optimise Treturn
Hot Oil Circuits (cont.)
T*
Now:
290o
Tsupply = 300o
∆Tmin = 20 OC
in
m
CP
Treturn = 130o
min
Pinch
120o
≈
∆H
Hot Oil Circuits (cont.)

T*
290o
∆Tmin = 20 OC
The Pinch does not
need to be limiting.
in
m
CP
Pinch
120o
≈
∆H
Number of Steam Levels
T*
QHmin
Many
levels
possible
Each level
costs complexity
Pinch
∆H
Don't go mad!
Generate steam below pinch
T*
≈
Pinch
180O
140O
Steam
100O
60O
Cooling
20O
Water
≈ QCmin
0 20 40 60 80 100 ∆H
BFW Pre-heat and Superheat
Steam generation with boiler feedwater pre-heat and superheat
T*
≈ Pinch
160o
140o
Point of closest
approach-
120o not necessarily at
the boiling point
100o
Superheat Evaporation Pre-
80o heat
60o
40o Cooling
Water
20o QCmin
0 ∆H
When to use pockets?

SOMETIMES, the pocket should be used
T* T*
HP Steam HP Steam
Generation Generation
LP Steam
Useage
CW CW
∆H ∆H
IF (1) the pocket spans the temperature of two utilities.

(2) the heat duty within the pocket is big enough to make it worthwhile.
Limiting Stack Temperature
T*
TTFT
To
TPinch
in
m
CP
QHmin
TPinch TTFT
Tacid dew
TTFT = theoretical flame temperature
To Tacid dew = acid dew point
∆H TO = ambient
Pinch temperature might be limiting stack temperature.
Mixture of flue gas and steam
T* T*
FG
FG
➩ LP
∆H ∆H
Note:
Flue gas cooled down to pinch
Refrigeration
T*
CW
-5 OC
-40 OC
-70 OC
∆H
Place Refrigeration Levels like Steam Levels

Summary
• The grand composite curve can be constructed directly

from the problem table algorithm.
• Grand composite curve shows utility requirements in
enthalpy and temperature terms.
• Temperature differences built into the construction.
• Best tool for utility placement.
• Balanced composite curves give the true picture (after
utility selection).

Utilities and Utilities Targeting: Utilities For A Process

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Lecture 6

Utilities and Utilities Targeting

Utilities for a process

Furnace Hot Oil

We normally have a choice of many hot and cold utilities.

• Steam HP, MP, LP

• Gas turbine exhaust

• Heat pump reject

• Heat pump heat sink

We want to USE at the LOWEST level Lowest cost

Cold Utilities: Generation and Use

We want to USE at the HIGHEST level Lowest cost

Boiler Feedwater Treatment

Raw Water Boiler BFW Condensate Return

RADIANT Radiant Section Tubes

Designs vary according to application

TTFT = Theoretical Flame Temperature

Hot Oil Circuits

What is the minimum hot oil flowrate ?

How do we target for the

➪ The Grand Composite Curve

Let's plot this on a T - H diagram.

The Problem Table

QCmin = 20 Cold Utility

Heat Source and Heat Sink on GCC

cold utility requirements of the process

both in ENTHALPY AND TEMPERATURE

GCC and Utility Placement

A new pinch (utility pinch) is created

Hot Oil Circuits

Capital Costs Energy Costs

Hot Oil Circuits (cont.)

Generate steam below pinch

When to use pockets?

IF (1) the pocket spans the temperature of two utilities.

Pinch temperature might be limiting stack temperature.

Mixture of flue gas and steam

Place Refrigeration Levels like Steam Levels

• The grand composite curve can be constructed directly

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