PED-III - Heat Exchanger Networks - AK Golder PDF

Process Equipment Design-III (CL 403)
Design of Heat Exchanger Network (HEN)
Dr. Animes K Golder
Department of Chemical Engineering

Indians Institute of Technology Guwahati
Assam - 781039
Course Syllabus
• Design of heat exchanger network: Setting energy targets, problem table

algorithm, heat recovery pinch, heat exchanger network (HEN)
representation, HEN design for maximum recovery, stream splitting,
capital energy trade offs.
• Principles of multi-component distillation and design: Basic distillation

design, sequencing of simple distillation columns, complex distillation
columns, short-cut modeling of complex columns.
• Design of azeotropic and extractive distillation systems.
Pre-requisites
• Process Equipment Design I (CL 206), Process Equipment Design II (CL

304) and Mass Transfer Operations I (CL 205) 2
Texts - Design of Heat Exchanger Network
“CHEMICAL PROCESS: DESIGN AND INTEGRATION” by R. Smith, John Wiley & Sons
Ltd. 2005.
“PINCH ANALYSIS AND PROCESS INTEGRATION: A User Guide on Process Integration for
the Efficient Use of Energy” by I.C. Kemp, Elsevier, 2007.
3
Grading Scheme
Mid semester exam : 30%

End semester exam : 30%

Quizzes / class tests : 10%
Tutorials & assisnments : 30%
Important Instructions
o Not be allowed to enter the class room after 2 minutes from the commencement of
the lecture
o Minimum attendance is 75% to write the end-semester examination
o Must carry graph paper, scale, calculator, eraser and supplementary pages to
the tutorial classes
o Mid semester and end semester quizzes may be conducted without prior
intimation
4
What is meant by
o Design of Heat Exchanger?
o Design of Heat Exchanger Network (HEN)?
5
Classification of heat exchangers depending on the applications
Heat exchanger may have singe or two
phase flow on each side
Fixed tubesheet
Flow
Shell & tube U-tube
Cross Parallel Counter Removable bundle
Tubular Spiral tube Floating head
Double pipe
Finned tube
Indirect Extended surface

contact-type
Finned plate
Recuperative Gasketed plate
Plate Spiral plate
Lamella
Direct
contact-type
Heat
Exchanger Disk type
Rotary
regenerator
Regenerative Drum type
Fixed-matrix 6
regenerator
Fixed-tube heat exchanger Floating-head heat exchanger
Removable U-tube heat exchanger
7
Typical parts and connections of Heat Exchangers
1. Shell 16. Tubes (U-type)
2. Shell cover 17. Tie rods and spacers
3. Shell flange (channel end) 18. Transverse (or cross) baffles or support plates
4. Shell flange (cover end) 19. Longitudinal baffles
5. Shell nozzle or branch 20. Impingement baffles
6. Floating tube sheet 21. Floating head support
7. Floating head cover 22. Pass partition
8. Floating head flange 23. Vent connection
9. Floating head gland 24. Drain connection
10. Floating head backing ring 25. Instrument connection
11. Stationary tube sheet 26. Expansion bellows
12. Channel or stationary head 27. Support saddles
13. Channel cover 28. Lifting lugs
14. Channel nozzle or branch 29. Weir
15. Tube (straight) 30. Liquid level connection
8
Process (thermal) design procedure of Heat Exchanger
[Kern method ]
A  U o ,assm . LMTD
Q
. FT
A
nt 
 do L
9
.
4m(n p / nt )
u
 di 2
.
4 m(n p / nt )
Re   104
 di 

 1.0
w
10
U o ,cal  U o ,assm
0  30%
U o ,assm
A - Areqd
% Overdesign = 100
Areqd
11
If the tube-side pressure drop exceeds the allowable pressure drop for the process system,
decrease the number of tube passes or increase number of tubes per pass. Go back to step
#6 and repeat the calculations steps.
If the shell-side pressure drop exceeds the allowable pressure drop, go back to step #7 and
repeat the calculations steps.
Step #15. Upon fulfillment of pressure drop criteria, go mechanical design.
12
Selection of Fluids for Tube and Shell Side
• Routing of the shell side and tube side fluids has considerable effects on the heat
exchanger design. Some general guidelines for positioning the fluids are given in
Table
• These guidelines are not ironclad rules and the optimal fluid placement depends on
many factors that are service specific
Tube-side fluid Shell-side fluid

Corrosive fluid Condensing vapor (unless corrosive)
Cooling water Fluid with large temperature difference (>40°C)
Fouling fluid
Less viscous fluid
High-pressure steam
Hotter fluid
Heat Exchanger Networks: Shell- and -Tube Heat Exchangers
1 shell pass and 1 tube pass

o Needs lower area than 1-2 design
Ideal shell side flow
1 shell pass and 2 tube passes
o Allowance of thermal expansion

o Easy mechanical cleaning Non-ideal shell side flow
14
o Good heat transfer coefficient
Effect of Temperature Differences on Design of Shell and Tube Heat Exchanger
Countercurrent flow Cocurrent flow
Cross
Approach
1-1 exchanger flow 1-2 exchanger flow
15
(R)
(P)
FT expressions in 1-2 shell and tube

heat exchanger:
ln
16
17
Effect of terminal temperatures on FT
Infeasible design of a single 1-2 exchanger at higher temperature cross

18
Temp cross Temp cross
Temp cross Temp cross
o Situation of high temperature cross can be taken care by placing the

shells in series of 1-2 type.
o However different kinds of shells or multiple shells also can be an
alternative. 19
Maximum Thermal Effectiveness of 1-2 Shell and Tube Exchanger
and FT to be determinate if:
Always true for feasible
heat transfer
ln
Both condition to satisfy
20
Design value of ‘P’: P  X P Pmax , 0<X P  1
21
Bowman RA. Mean Temperature Difference Correction in
Multipass Exchangers, Ind. Eng. Chem. 1936 (28) 541-544.
Value of P over NSHELLS number of 1-2 shells in series (PN-2N) can
be related to P for each 1-2 shell (P1-2) as:
23
24
Heat Exchanger Networks: Energy Targets
Reactor
Separation & Recycle System
Heat Recovery System
Heating & Cooling Utilities

Water & Wastewater Treatment
Onion model
25
Prof. Bodo Linnhoff (born 1948) who developed Pinch
Analysis of Heat Exchanger Network Design
[University of Manchester Institute of Science and Technology (UMIST)]
Born in Berlin, Germany, Linnhoff studied at Technical University of Hanover,
Germany and ETH Zurich, Switzerland (MSc in Mechanical Engineering). He
taught at ETH until 1974 when he went to University of Leeds, UK, as a British
Council Scholar. There he gained a PhD in Chemical Engineering (1979). He
joined the company ICI in 1977 and moved to the University of Manchester
Institute of Science and Technology (UMIST) in 1982 where he was appointed to
a Chair in Chemical Engineering.
He joined GoMedia in 2015 and involved with GoMedia's first multi territory
launch in Europe, he is now heading up GoMedia’s European sales function based
in Brussels. 26
Temperature–enthalpy diagram
27
Composite Curves
28
Two-stream heat recovery problem
29
30
31
Flowsheet of a Manufacturing Unit
ΔH=27 MW
ΔH=-30 MW
Feed 2 230ºC
Product 2
140ºC Reactor 2
200ºC 80ºC
ΔH=32 MW
Off Gas
Feed 1 Reactor 1 40ºC
20ºC 180ºC 250ºC
ΔH=-31.5 MW
Coln
40ºC
Product 1
40ºC
o Total hot streams heat duty=61.5 MW (Surplus)

o Total cold streams heat duty=59 MW (Deficit)
Folwsheet with two hot streams and two cold streams

32
Formation of Hot and Cold composite curves
Stream Type
no.
#1 Cold 20 180 32 0.2
#2 Hot 250 40 -31.5 0.15
#3 Cold 140 230 27 0.3
#4 Hot 200 80 -30 0.25
250
200
PINCH
150
Cold composite curve
Hot composite curve
T, C
o
o
Tmin=10 C
100
50
0
0 10 20 30 40 50 60 70
H, MW
MW 10= QCmin QRecovery=51.5 QHmin =7.5 MW 33
Contd..
250
200
PINCH
150
Hot composite curve Cold composite curve
T, C
o
o
Tmin=20 C
100
50
0
0 10 20 30 40 50 60 70 80
H, MW
MW 14= QCmin QRecovery=47.5 QHmin =11.5 MW
o Overlap between the composite curves represents the maximum

amount of heat recovery possible
o Overshoot at the bottom represents the minimum amount of external
cooling required
o Overshoot at the top represents the minimum amount of external
heating required
Trade-off between energy and capital cost and an economic amount
of energy recovery
35
Heat transfer from above
the pinch to below the
pinch is possible
Heat transfer from below

to above the pinch is not
possible without violating
ΔTmin
37
37
3 forms of cross pinch heat transfer
Increase the
requirement of both
hot and cold utilities
by the same amount
i.e. utility
requirement increase
Process-process heat
is DOUBLE
transfer across the pinch
Inappropriate utility below the
pinch cause enthalpy imbalance
below the pinch
Designer must not allow transfer

heat across the pinch:
o Process-to-process heat
transfer
o Inappropriate use of utilities
Inappropriate utility above the pinch cause 38
enthalpy imbalance above the pinch
Threshold Problems
Threshold problem: Only cold utility required

39
Threshold Problems (contd.)
Threshold problem: Only hot utility required

40
41
Introduction of an additional utility to create ‘UTILITY PINCH’
Two levels of Hot utility

Two levels of Cold utility
42
Steam classification
Steam grade Typical pressure, Steam cost (major components):
psig CG = f(CF, Hg, hf, ηB)
Low pressure (LP) Upto 25 CF = Fuel cost (~ 90% of total cost)
Medium pressure (MP) 25-125 Hg = Enthalpy of steam
High pressure (HP) >125 hf = Enthalpy of boiler feedwater
ηB = Boiler efficiency
43
Steam valuation estimated by convention method
Source:
https://www1.eere.energy.gov/manufacturing/tech_assistance/pdfs/tech_brief_true_cost.pdf
44
Problem Table Algorithm
45
Example Problem Table Algorithm ΔTmin=10°C
Stream no. Type TS, °C TT, °C ΔH, MW CP, MW.K-1 T*S, °C T*T, °C
1 Cold 20 180 32 0.2 25 185
2 Hot 250 40 -31.5 0.15 245 35
3 Cold 140 230 27 0.3 145 235
4 Hot 200 80 -30 0.25 195 75
Shifted temperature
intervals, *T, (°C)
245 2 250
235 240 230
195 200 190 4 200
185 180 190 180 190

145 140 150 140 150
3
75 70 80 80
35 30 40
25
1
Temperature interval heat balances
47
Problem Table Cascade
HOT HOT
UTILITY UTILITY
245°C 0 MW 7.5 MW
ΔH= -1.5 ΔH= -1.5
235°C 1.5 MW 9.0 MW
ΔH= 6.0 ΔH= 6.0
195°C -4.5 MW 3.0 MW
ΔH= -1.0 ΔH= -1.0
185°C -3.5 MW 4.0 MW
ΔH= 4.0 ΔH= 4.0
145°C -7.5 MW 0 MW
ΔH= - 14.0 ΔH= -14.0

75°C 6.5 MW 14 MW
ΔH= 2.0 ΔH= 2.0
35°C 4.5 MW 12 MW
ΔH= 2.0 ΔH= 2.0
25°C 2.5 MW 10 MW
COLD UTILITY COLD UTILITY
Cascade surplus heat from Heat added to hot utility to make48

high to low temperature all heat flows zero or positive
EXAMPLE
GCC and utility selection
Hot utility=7.5 MW
Cold utility= 10 MW (20-30°C)
Balanced composite curve for multiple utilities
240
Utility pinch
200
Process pinch
Temperature (oC)
160
o
Tmin=180-170=10 C
120
o
Tmin=150-140=10 C
80
40
0
0 10 20 30 40 50 60 70
H, MW 50
Grand Composite Curve (GCC)
Although the composite curves can be used to set energy targets, however, the grand
composite curve (GCC) is a more appropriate tool for understanding the interface
between the process and utility system
51
Grand composite curve allows alternative utilities
Grid representation of streams
52
Heat Exchanger Networks: Number of Heat Exchange Units,
Number of Shells, Heat Exchange Area and Cost Targets
Major components that contribute to capital cost of heat exchanger network:

o Number of units
o Heat exchange area
o Number of shells
o Materials of construction
o Heat exchanger type
o Pressure rating
53
Heat Exchange Area Targets
Utility streams must be included with the process streams in the composite
curves to obtain the Balanced Composite Curves to calculate the network
area
250
Balanced Composite Curve
200
PINCH
150
T, C
o
o
Tmin=20 C
100
50
0
0 10 20 30 40 50 60 70 80
H, MW
54
Effect of individual stream film transfer coefficients can be
included to calculate network area
FT correction factor for each enthalpy interval depends both on the assumed
value of XP and the temperatures of each interval on composite curves. The above
55
equation can simply modify by incorporating FT in each interval for 1-2 pass
Balanced composite curve and temperature interval
200 o
o
179.57 C
180 179 C o
o
180 C
170 C
160
o
150 C
140
Temperature, C
o
120 C
o
120
o
100 90 C
o
110 C
o
80
o o 102.5 C 105oC
50 C 60 C o
80 C
60
o o
40 40 C 50 C
o
30 C
20 o o
20 C 22.5 C
0 10 20 30 40
H, MW
• Given data: Film transfer coefficients for all streams are 200 W·m−2·K−1 56
(including utility)
Target area calculation
Enthalpy intervals and stream population
Interval  1 2 3 4 5 6 7
180ºC 179.571ºC 179ºC

Steam
(qi= 3) (qi= 4) Aarea above the pinch, (target) =
150ºC 90ºC 60ºC 50ºC
8,859 m2
1
(qi= 12) (qi= 6) (qi= 2)
170ºC 150ºC 90ºC 60ºC 50ºC 40ºC
2 Aarea below the pinch, (target) =
(qi= 2) (qi= 6) (qi= 3) (qi= 1) (qi= 1) 10,469 m2
120ºC 110ºC 105ºC 102.5ºC 80ºC 50ºC

3
(qj= 3) (qj= 1.5) (qj= 0.75) (qj= 6.75) (qj= 9)
110ºC 105ºC 102.5ºC 80ºC

4
30ºC 22.5ºC 20ºC
(qj= 2.5) (qj= 1.25) (qj= 11.25) CW
(qj= 3) (qj= 1)
PINCH
Enthalpy  (q i / hi ) k  (q j / h j )k Ak (m2)
ΔTLMk (1-1 pass, FT=1.0)
interval Hot streams Cold streams
1 64.67 (ΔT1=60, ΔT2=69.571) 15,000 15,000 463.9
2 71.76 (ΔT1=69.571, ΔT2=74) 20,000 20,000 557.4
3 55.79 (ΔT1=65, ΔT2=47.5) 10,000 10,000 358.5
4 24.07 (ΔT1=47.5, ΔT2=10) 90,000 90,000 7478.2
5 10 (ΔT1=10, ΔT2=10) 45,000 45,000 9000
6 28.73 (ΔT1=30, ΔT2=27.5) 15,000 15,000 1044.2
7 23.55 (ΔT1=27.5, ΔT2=20) 5,000 5,000 424.6 57
Target area for the network,  Ak = 19,327
Number of Shells Targets
Where,
NSHELLS = Total number of shells over K enthalpy intervals
Nk = Real (or fractional) number of shells resulting from the temperatures of

enthalpy interval k
Sk = Number of streams in enthalpy interval k
58
Capital Cost Targets
Cost a single heat exchanger with surface area A can be expressed as:
Installed Capital Cost of Exchanger = a + bAc
Where,
a, b, c = Constants that vary according to materials of construction, pressure
rating and type of exchanger.
Network Capital Cost = N[a + b(ANETWORK /N)c]
Where,
N = number of units or shells, whichever is appropriate
[J. Douglas, Conceptual Design of Chemical Processes, McGraw Hill, 1989]
59
Heat Exchanger Networks: Pinch Method
of Network Design
Two  rules:
o Process-to-process heat transfer 
o Inappropriate use of utilities 
i. Start at the pinch: Most constrained region of the problem.
ΔTmin exists between all hot and cold streams at the pinch. Number of feasible
matches in this region is severely restricted.
ii. CP inequality for individual matches at ‘PINCH’
CPH ≤ CPC (above pinch)

CPH ≥ CPC (below pinch)
iii. CP-Table
Identification of the essential matches in the region of the pinch. CP values of the
hot and cold streams for the streams at the pinch are listed in descending order
60
iv. Tick-off heuristic
Grid diagram
Criteria for pinch

matches above the
pinch
61
Infeasible match Feasible match
Criteria for pinch
matches below the pinch
Infeasible match Feasible match

‘CP-Table’ for the design
above & below the pinch
62
Above pinch Below pinch
Tick-off heuristic
To tick off a stream, individual units are made as large as possible i.e. the smaller of
the two heat duties on the streams being matched to keep the number of units to a
minimum
Sizing the units above the pinch using tick-off heuristics
Sizing the units below the pinch using tick-off heuristics

63
Minimum number of units=(S-1)above pinch + (S-1)below pinch=(5-1)+(4-1)= 7
Design for Threshold Problems
o If there is no pinch, the design is started at the most constrained region i.e.
where temperature difference is smallest.
o In case of Utility pinch(es), threshold problem can be treated as a pinched

problem.
Minimum temperature difference end
Utility demand
Network design using Pinch method
64
Utility demand
Threshold problem
Pseudo-pinch
65
Network design using Pinch method
Stream Splitting
Splitting of the cold
streams is required if the
number of hot streams at
the pinch, above the
pinch, is more than the
number of cold streams.
SH ≤ SC (above pinch)
Splitting of the hot

streams is required if the
number of cold streams
at the pinch, below the
pinch, is more than the
number of hot streams.
66
SH ≥ SC (below pinch)
CP inequality criteria necessitates stream splitting
CPH ≤ CPC (above pinch)
CPH ≥ CPC (below pinch)
Above
pinch
Below
pinch
67
Algorithms for Stream Splitting
Above pinch
Below pinch
68
Network Design with Stream Splitting
EXAMPLE. Streams data of a high temperature process reveals that for ΔTmin = 20°C. The
process requires 9.2 MW of hot utility and 6.4 MW of cold utility and the pinch is located
at 520°C on hot stream. The network is designed for maximum energy recovery.
Stream type Supply Temp. Target Temp. (ºC) Heat capacity flow rate
(ºC) (MW.K-1)
Hot (#1) 720 320 0.045
Hot (#2) 520 220 0.04
Cold (#3) 300 900 0.043
Cold (#4) 200 550 0.02

 
Infeasible match at Stream splitting to have Design of network
pinch above pinch feasible match at pinch 69
above pinch
Stream grid diagram

  
70
Network design for multiple pinches
Two process pinches: Both hot and cold steams are parallel
250
CP=0.15
200
Temprature, Deg C
Design between process pinches

150
Tmin=20 Case 1: At any end
Case 2: Start at above pinch
100
(Like below pinch problem)
Case 3: Start at below pinch
50
Tmin=20 (Like above pinch problem)
0
0 10 20 30 40 50
Enthalpy, kW
Between the process pinches there may be

Case 1: One hot stream and one cold stream (CP of both streams=0.15)
Case 2: One hot stream (CP=0.15) and more than one cold streams (CP < 0.15 for individual stream)
Case 3: One cold stream (CP=0.15) and more than one hot streams (CP < 0.15 for individual stream)
Case 4: Stream splitting??
Design of HEN with multiples process pinches
250
200
Temperature, Deg C
150
Tmin=20
100
50
Tmin=20
0
0 10 20 30 40 50
Enthalpy, kW
Design between process pinches

Case 1: Both streams parallel
Start at any end
Case 2: Streams not parallel
 For above pinch subject to CPhot>Cpcold (Like below pinch problem)
 For below pinch subject to CPcold>Cphot (Like above pinch problem) 72
Remaining Problem Analysis
o Along with the number of units and maximum energy recovery; heat
transfer area, number of shells when using 1-2 shells and capital cost
need to consider
o When a match is placed (provided multiple choices are available) the

penalty (energy, network area, shells , cost) is calculated by determining
the targets for the Remaining Problem without completing the entire
Network design
o The difference between the Energy Targets before placing a match and
Energy Targets of the Remaining Problem plus Energy Duty for that said
match will give the energy penalty for that match
o Similarly, the penalty of Network Area, Shells and Costs can determined
by the Remaining Problem 73
Hand on Calculation on Remaining Problem Analysis
EXAMPLE:
a. Develop a maximum energy recovery design above the pinch that comes close to the
area target in the minimum number of units.
b. Develop a maximum energy recovery design below the pinch that comes as close as
possible to the minimum number of units.
Data available:
(i) Low pressure steam is available condensing between 180 and 179°C
(ii) Cooling water between 20 and 30°C
(iii) All film transfer coefficients are 200 W·m−2·K−1 (both hot and cold streams)
(iv) ΔTmin = 10°C (pinch at 90°C on the hot streams and 80°C on the cold streams)
(v) Minimum hot and cold utility duties are 7 MW and 4 MW
Stream type Supply Temp. (ºC) Target Temp. (ºC) Heat capacity flow rate
(no.) (MW.K-1)
Hot (#1) 150 50 0.2
Hot (#2) 170 40 0.1
Cold (#3) 50 120 0.3
Cold (#4) 80 110 0.5 74
Design above the pinch
CPH ≤ CPC 
SH ≤ SC 
Pinch
CP
150°C 90°C
1
0.2
170°C 90°C
0.1 2
120°C 80°C
0.3 3
110°C 80°C
0.5 4
o Four feasible matches at pinch above pinch

o Which one to select?
o Solution Remaining Problem Analysis
75
Balanced composite curve and temperature interval
200 o
o
179.57 C
179 C o
180
o
180 C
170 C
160
o
150 C
140
Temperature, C
o
120 C
o
120
o
100 90 C
o
110 C
o o
80 102.5 C 105 C
o o
50 C 60 C o
80 C
60
o o
40 40 C 50 C
o
30 C
20 o o
20 C 22.5 C
0 10 20 30 40
H, MW
76
Target area calculation
Enthalpy intervals and stream population
Interval  1 2 3 4 5 6 7
180ºC 179.571ºC 179ºC Aarea above the pinch, (target) =

Steam
(qi= 3) (qi= 4)
8,859 m2
150ºC 90ºC 60ºC 50ºC
1
(qi= 12) (qi= 6) (qi= 2)
Aarea below the pinch, (target) =
170ºC 150ºC 90ºC 60ºC 50ºC 40ºC
10,469 m2
2
(qi= 2) (qi= 6) (qi= 3) (qi= 1) (qi= 1)
120ºC 110ºC 105ºC 102.5ºC 80ºC 50ºC

3
(qj= 3) (qj= 1.5) (qj= 0.75) (qj= 6.75) (qj= 9)
110ºC 105ºC 102.5ºC 80ºC

4
30ºC 22.5ºC 20ºC
(qj= 2.5) (qj= 1.25) (qj= 11.25) CW
(qj= 3) (qj= 1)
Enthalpy  (q i / hi ) k  (q j / h j )k Ak (m2)
ΔTLMk (1-1 pass, FT=1.0)
interval Hot streams Cold streams
1 64.67 (ΔT1=60, ΔT2=69.571) 15,000 15,000 463.9
2 71.76 (ΔT1=69.571, ΔT2=74) 20,000 20,000 557.4
3 55.79 (ΔT1=65, ΔT2=47.5) 10,000 10,000 358.5
4 24.07 (ΔT1=47.5, ΔT2=10) 90,000 90,000 7478.2
5 10 (ΔT1=10, ΔT2=10) 45,000 45,000 9000
6 28.73 (ΔT1=30, ΔT2=27.5) 15,000 15,000 1044.2
7 23.55 (ΔT1=27.5, ΔT2=20) 5,000 5,000 424.6 77
Target area for the network,  Ak = 19,327
tc 2  tc1 th1  th 2
TARGETING the number of shells (1-2 exchanger) P R
th1  tc1 tc 2  tc1
Values Interval Interval Interval Interval Interval Interval Interval

(1) (2) (3) (4) (5) (6) (7)
;
RK 0.0429 0.1142 8 2.66667 1 1.33333 4
PK 0.14286 0.06705 0.03704 0.32143 0.75 0.2 0.08333
WK 8.06579 5.97175 0.17443 0.36369 -- 0.72727 0.26261
When, NK 0.0709 0.03454 0.17962 1.54049 2.6904 0.27323 0.23817
Xp =0.9 FT 0.999 0.999 0.997 <0.5 <0.5 0.985 0.992
(not acceptable) (not acceptable)
Pk, max -- -- -- Pmax= 0.307 Pmax= 0.586 -- --
Pk=Xp*Pmax -- -- -- 0.2763 0.5274 -- --
FT -- -- -- 0.792 0.739 -- --
(modified ) (Rk =1)
(can be accepted?)
WK 3.63994 3.14065 0.32529 0.50146 --- 0.8 0.40969
NK 0.115 0.0539 0.2793 2.257 3.828 0.3899 0.3567
When, FT 0.999 0.999 0.997 <0.5 < 0.5 0.985 0.992
Xp =0.75 (not acceptable) (not acceptable)
Pk, max -- -- -- 0.307 0.586 -- --
New Pk =Xp*Pmax -- -- -- 0.23025 0.4395 -- --
FT -- -- -- 0.916 0.888 -- --
(New ) (acceptable) (acceptable)
Final &
acceptable, 0.999 0.999 0.997 0.916 0.888 0.985 0.992
FT
K1orK2 (0.115×1) + (0.0539×2) + (0.2793×2) + (2.257×3) + (3.828×2) + (0.3899×2) +(0.3567×1)
 N (S 1)
k 1
k (Nshells)above pinch = 7.5524 ≈ 8
(Nshells)below pinch = 8.7925 ≈ 9 , NSHELL (TOTAL) = 17
78
(Contd.) Xp=0.75
Values Interval Interval Interval (3) Interval Interval Interval Interval
(1) (2) (4) (5) (6) (7)
A1-1 pass, m2 463.9 557.4 358.5 7478.2 9000 1044.2 424.6
A1-2 pass, m2 464.4 557.9 359.6 8163.9 10135.1 1060.1 428
For 1-2 pass exchanger:
Atarget(above pinch)=9545.8 m2
Atarget(below pinch)=11623.3 m2
Atarget(total)=21169.1 m2
N(i)above pinch N(steam)=0.1689, N(1)=2.257, N(2)=2.5363, N(3)= 2.7052; N(4)=2.5902
K1
 N (i)
i
=10.2576;
above pinch
N k =2.7052
k 1
(Nshells)above pinch = 7.5524
N(i)below pinch N(CW)=0.7466, N(1)=4.2179, N(2)=4.5746, N(3)=3.828;

K2
 N (i)
i
below pinch =13.3671; N
k 1
k =4.5746
(Nshells)below pinch = 8.7925
N(i) is greater for all stream except steam & cooling water and recalculated for N(steam)=1 and N(CW)=1.
(Nshells)above pinch = 8.3835 [(Nshells)above pinch=9] 79
(Nshells)below pinch = 9.0459 [(Nshells)below pinch =10]
Maximum Thermal Effectiveness of 1-2 Shell and Tube Exchanger
Always true for feasible

heat transfer
80
Target for the remaining problem after match between [1] and [3]:
[1-1 Shell- and -Tube Exchanger]
CP
150°C  90°C
0.2 1
170°C 90°C ∆T1 = 10, ∆T2 = 30
0.1 2
∆TLM = 18.2
A1 = 6593 m2
120°C
 80°C 3
0.3
110°C 80°C 4
0.5
o o
CCC 179 C 180 C
180
HCC o
Steam (Hot utility) 170 C
160
Internal (1): ∆T1 = 83, ∆T2 = 70, ∆TLM = 76.31, A1 = 917.3 m2
Interval
Internal (2): ∆T1 =74, ∆T2=10, ∆TLM=31.98, A2=2501.56 m2
Temperature ( C)
#1
140

Interval
#2
120 H=7 Target area for the remaining problem above pinch
H=8
110 C
o (A1 + A2) = 3419 m2
Overall target exceed by = [{6593+3419) – 8859}/8859] × 100
100
o
o
90 C 96 C
80 o
= 13 %
80 C
10 12 14 16 18 20 22 24 26 28
H (MW)
Balanced composite curve of the 81

Remaining Problem
CP
150°C  90°C
0.2 1
170°C 90°C ∆T1 = 10, ∆T2 = 46
0.1 2
∆TLM = 23.59
A1 = 5087 m2
120°C 80°C 3
0.3
104°C

110°C 80°C 4
0.5
o o
CCC o 179.57 C 180 C
180 179 C
HCC
Steam 170 C
o
o
Internal (1): ∆T1 = 60, ∆T2 = 69.571, ∆TLM = 64.67, A1 = 463.9 m2
162 C
Internal (2): ∆T1 = 69.571, ∆T2 = 74, ∆TLM = 71.76, A2 = 557.4 m2
Interval Interval
160 #2 #1
Interval
#3 Internal (3): ∆T1 = 65, ∆T2 = 58, ∆TLM = 61.43, A3 = 130.2 m2
Temperature ( C)
o
140
Internal (4): ∆T1 = 58, ∆T2 = 10, ∆TLM = 27.3, A4 = 2636.8 m2
   
120
Interval o
o
120 C Target area for the remaining problem above pinch
104 C o
100 #4 105 C
o 110 C
(A1 + A2 + A3 + A4) = 3788 m2
Overall target exceed by = [{5087+3788) – 8859}/8859] × 100 = 0.2 %
o
90 C
80 o
80 C
10 12 14 16 18 20 22 24 26 28 30
H(MW)
Remaining Problem
CP
150°C 90°C
0.2 1
0.1 2
170°C  90°C ∆T1 = 10, ∆T2 = 74
∆TLM = 31.98
A1 = 2502 m2
0.3 120°C 80°C 3

110°C 96°C  80°C 4
0.5
o
179 C 179.57 C 180 C
o o
CCC
180
HCC Internal (1): ∆TLM = 64.667, A1 = 463.9 m2
160
Steam
Interval
Internal (2): ∆TLM = 71.67, A2 = 557.4 m2
o
150 C #1 Internal (3): ∆TLM = 29.47, A3 = 2443.5 m2
Temperature ( C)
Interval
Internal (4): ∆TLM = 13.61, A4 = 3526.7 m2
o
140
#2 H=3
Interval
o H=4
120 114 C
Target area for the remaining problem above pinch
#3
H=7.2 o
120 C
100
Interval
#4 o
o
110 C (A1 + A2 + A3 + A4) = 6991.5 m2
105 C
o
90 C
H=4.8 96 C
o
Overall target exceed by = [{6991.5+2502) – 8859}/8859] × 100 =
80 o
80 C 7.2 %
8 12 16 20 24 28
H (MW)

Remaining Problem
Complete network design ‘Above Pinch’
CP
90°C
0.2 150°C

1
90°C
170°C
0.1
2

80°C
0.3 120°C 106.67°C 3
H
4 MW 8 MW 80°C
110°C 104°C 4
0.5 H
3 MW 12 MW
84
Design below the pinch
o Stream Splitting Needed
Pinch
90°C  60°C 50°C
CP ∆H
1
0.2 8
90°C 40°C
2 0.1 5
80°C 50°C
8 MW
 3 0.2 6
0.1 3
Pinch
90°C  60°C 50°C
CP ∆H
1
0.2 8
2
90°C  60°C 40°C
0.1 5
80°C 50°C
 3 0.2 6
6 MW
85
3 MW
 0.1 3
Complete network design ‘Below Pinch’
Pinch
CP ∆H
90°C 60°C 50°C
1 C 0.2 8
2 MW
90°C 60°C 40°C 0.1 5
2 C
2 MW
80°C 0.2 6
50°C 3
6 MW 0.1 3
3 MW
86
Complete Network Design
1
150°C 90°C 60°C 50°C
C
170°C 90°C 60°C 2 MW
2 C
2 MW
120°C 106.67°C 80°C 50°C

H 3
4 MW 8 MW 80°C 6 MW
4
110°C 104°C
H
3 MW 12 MW 3 MW
Utility
Exchanger Utility Process
Exchanger Exchanger
1
4
3
Utility
Utility Exchanger 87
Exchanger
Modification for 1-2 shell & tube exchanger with Xp=0.75
FT A1-1 PASS, A1-2 PASS, Area
N
Sl Match FT (Final & m2 m2 per
R W PMAX P=Xp*PMAX (No. of
no. between (Old) acceptable) Shell,
Shells)
m2
1 [1]-[4] 2.5 0.520 <0.5 0.32297 0.24223 0.913 5087 5571.6 3 1857.2
2 [2]-[3] 2.99 0.470 <0.5 0.27953 0.20964 0.921 2770 3007.2 3 1002.4
6
3 [3]- [Stm] 0.07 3.399 0.999 --- --- 0.999 606.4 607 1 6072
5
4 [4]- [Stm] 0.16 2.837 0.999 --- --- 0.999 413.9 414.4 1 414.2
7
5 [1]-[3] 1 --- <0.5 0.58579 0.43934 0.887 6000 6764.4 4 1691.2
(CP=0.2)
6 [2]-[3], 1 --- <0.5 0.58579 0.43934 0.887 3000 3382.2 4 845.5
(CP=0.1)
7 [1]-[CW] 1 --- 0.981 ---- --- 0.981 666. 7 679. 6 1 679.6
(R=1)
8 [2]-[CW] 2 0.598 0.942 --- --- 0.942 810.9 860.9 1 860.9
Adesign(above pinch)=9600.2 m2 Atarget(above pinch)=9545.8 m2

Adesign(below pinch) =11687.0 m2 Atarget(below pinch)=11623.3 m2
Adesign(total) =21287.2 m2 Atarget(total) =21169.1 m2
Aexcess = 118.1 m2 88
Network Optimization
Degree of freedom: Loops, utility path and stream splitting
• Constrain of ΔTmin
can now be relaxed
• Heat duties can be

changed within a
loop without
changing the utility
consumption
89
Utility paths for the optimization of HEN
90
Multivariable optimization subject to:
o total enthalpy change on each stream being within a specified

tolerance of the original stream data
o nonnegative heat duty for each match
o positive temperature difference for each exchanger to be greater

than a practical minimum value for a given type of heat
exchanger
o for stream splits, branch flowrates must be positive and above a

practical minimum flowrate
91
Evolve the heat exchanger network in Figure to simplify its
structure
i. Remove the smallest heat recovery unit from the network by exploiting the degree
of freedom in a loop.
ii. Recalculate the network temperatures and identify any violations of the ΔTmin=
10°C constraint.
iii. Restore the original ΔTmin =10 °C throughout the network by exploiting a utility
path.
92
o Network with
6.5 MW of heat
shifted around
a loop
o Shows
infeasible
temperature
difference
93
10+x = 0.15(117.5-40)
94
Thank You
95

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Process Equipment Design-III (CL 403)

Design of Heat Exchanger Network (HEN)

Dr. Animes K Golder

Department of Chemical Engineering

• Design of heat exchanger network: Setting energy targets, problem table

• Principles of multi-component distillation and design: Basic distillation

• Design of azeotropic and extractive distillation systems.

• Process Equipment Design I (CL 206), Process Equipment Design II (CL

o Design of Heat Exchanger?

o Design of Heat Exchanger Network (HEN)?

Cross Parallel Counter Removable bundle

Tubular Spiral tube Floating head

Indirect Extended surface

Recuperative Gasketed plate

Plate Spiral plate

Regenerative Drum type

Removable U-tube heat exchanger

Step #15. Upon fulfillment of pressure drop criteria, go mechanical design.

Tube-side fluid Shell-side fluid

1 shell pass and 1 tube pass

1 shell pass and 2 tube passes

o Allowance of thermal expansion

Countercurrent flow Cocurrent flow

1-1 exchanger flow 1-2 exchanger flow

FT expressions in 1-2 shell and tube

Infeasible design of a single 1-2 exchanger at higher temperature cross

Temp cross Temp cross

o Situation of high temperature cross can be taken care by placing the

Both condition to satisfy

Separation & Recycle System

Heat Recovery System

Heating & Cooling Utilities

o Total hot streams heat duty=61.5 MW (Surplus)

Folwsheet with two hot streams and two cold streams

o Overlap between the composite curves represents the maximum

Heat transfer from below

Designer must not allow transfer

Threshold problem: Only cold utility required

Threshold problem: Only hot utility required

Introduction of an additional utility to create ‘UTILITY PINCH’

Two levels of Hot utility

185 180 190 180 190

ΔH= -1.5 ΔH= -1.5

235°C 1.5 MW 9.0 MW

ΔH= 6.0 ΔH= 6.0

195°C -4.5 MW 3.0 MW

ΔH= -1.0 ΔH= -1.0

185°C -3.5 MW 4.0 MW

ΔH= 4.0 ΔH= 4.0

ΔH= - 14.0 ΔH= -14.0

ΔH= 2.0 ΔH= 2.0

ΔH= 2.0 ΔH= 2.0

COLD UTILITY COLD UTILITY

Cascade surplus heat from Heat added to hot utility to make48

Major components that contribute to capital cost of heat exchanger network:

180ºC 179.571ºC 179ºC

120ºC 110ºC 105ºC 102.5ºC 80ºC 50ºC