CHE 165A L6 - HENs PDF

CHE 165 – Plant Design; D.
Wagner 1
Heat Exchange Networks (HENs)

Lecture 6 – Friday, September 27, 2019
2
Heat Integration Schematics

Simple Heat Exchange Network
• Look at a simple system:
T1
Hot Stream
Steam
t1 t2 t3
Cold Stream
T2
T3
CW
• How can we determine the optimal values for

T2 and t2?
© 2012 G.P. Towler / UOP. For educational use in conjunction with

Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
• We can plot temperature vs. duty:
Qhot
t3
T1
∆Tmin
Temperature
t2
T2
T3
t1
Qcold Qrec
Duty

• The maximum possible heat recovery is when the two
curves “pinch” and ΔTmin = 0
Qhot min
∆Tmin= 0 t3
TEMPERATURE T1
t2
T2
T3
t1
Qcold min
Qrec max
DUTY
• What happens as ∆Tmin approaches 0?
– Hot utility (steam) consumption is the lowest.
– Cold utility (cooling water) consumption is the lowest.
– We still need three heat exchangers
• 1 process-process exchanger.
• 1 process-hot utility exchanger.
• 1 process-cold utility exchanger.
• What is ∆Tlm for the process-process exchanger?
• How big is the process-process heat exchanger?

• We can see that changing ∆Tmin affects
– Utility requirements.
– Heat exchanger areas
• How can we find an optimum ∆Tmin?

– Design and cost the system for a range of ∆Tmin .
• Determine capital costs.
• Determine operating costs.
– Combine capital and operating costs to determine

an annualized cost
– Plot annualized cost vs. ∆Tmin
– Select the minimum
∆Tmin OPTIMIZATION
140
120
100
∆Tmin opt
Cost (10 $/y)

80
6
60
40
20
0
0 20 ∆Tmin 40 60
Utility Costs Annualized Capital Cost

Total Cost

Multi-stream Problems:
Composite Curves
• How do we handle multiple streams that have temperature
overlap?
• Stream data must be combined in such a way as to represent

the total energy sources and total energy demands in each
temperature range.
• The pinch method creates what is called a composite curve.

Composite Curves
• Consider a two stage reactor with reheat:
550° Rctr
Feed
#1 510° A 550°
Rctr
#2 520°
B 560°
To Next Reactor
Streams A and B have overlapping duties between 520° and 550°.

Composite Curves
• Multistage reactor example - stream data
Range T in T out Streams M*Cp Q
1 510 520 A 1 10
2 520 550 A 1 30
520 550 B 1 30
520 550 A+B 2 60
3 550 560 B 1 10
Plot T vs. Q for each temperature range.

Composite Curves
• Multistage reactor example - composite curve
570
560
TEMPERATURE (T)
550
540
530
520
510
500
0 20 40 60 80 100
Duty (Q)

Composite Curves
• There is an easy way to plot the composite curves:
just add up the Q values over each range of T
570
560
TEMPERATURE (T)
550
540
530
520
510
500
0 20 40 60 80 100
Duty (Q)

Composite Curves for UOP Platforming
Process
1000
800
Temperature (F)
600
400
200
0
0 50 100 150 200 250
Duty (MMBtu/h)

Composite Curves
QH
1000
800
Temperature (F)
• We can set targets

600 Pinch for hot and cold
utilities using the
400 composites, while
paying attention to
200 the process pinch
QC
0
0 50 100 150 200 250
Duty (MMBtu/h)

Composite Curves
QH
1000
800
Temperature (F)
• Since the duty scale

600 Pinch is a difference in
enthalpy, we can
400 slide the composite
curves horizontally,
200 increasing or
QC
decreasing ∆Tmin
0
0 50 100 150 200 250
Duty (MMBtu/h)

Composite Curves
QH
1000
800
Temperature (F)
600 Pinch • If we decrease ΔTmin

then our utility
400
targets are reduced
• What is the effect on
200
capital cost though?
QC
0
0 50 100 150 200 250
Duty (MMBtu/h)

Optimization of ΔTmin
• What happens as ∆Tmin is increased?
– More heat exchangers are required (extra cost)
– Log mean temperature differences are greater
• Each heat exchanger is smaller
• The cost for each heat exchanger decreases (cost savings)
– More utilities are consumed

• Cooling water demand increases
• Steam demand increases
• Utility costs increase
• Note: hot utility increase = cold utility increase
• How do we decide on the appropriate ∆Tmin?

– Same as the two-stream problem
– Plot Total Annualized Cost vs. ∆Tmin for the process
Optimization of ΔTmin
∆Tmin OPTIMIZATION
140
120
100
∆Tmin opt
Cost (10 $/y)
80
6
60
40
20
0
0 20 ∆Tmin 40 60
Utility Costs Annualized Capital Cost

Total Cost

Energy Costs
• Energy prices are often assumed to be well known
• See Ch6 & lecture on operating costs
• In practice, energy prices are affected by:

• Commodity nature of fuels
• Fuel mix
• Flaring of waste products (“fuel value” vs. disposal cost)
• Capital cost implications of fuel substitution
• So the actual energy price varies with time and is

seldom properly captured

THE CAPITAL – ENERGY TRADEOFF
Heat Exchanger Networks (HENs) design addresses
the following problem:
 Given:
 NH hot streams, each with given heat-capacity flow rate, Ch
supply temperature, Ths, and target temperature Tht
 NC cold streams, each with given heat-capacity flow rate, Cc
supply temperature, Tcs, and target temperature Tct
 Design:
 An optimal network of heat exchangers, connecting
between the hot and cold streams and between the streams
and cold/hot utilities.
 What is optimal?
 Implies a trade-off between CAPITAL COSTS (Cost of 21
equipment) and ENERGY COSTS (Cost of utilities).
STREAM REPRESENTATION IN Q-T DIAGRAMS
Hot stream T Cold stream
T
∆H ∆H
TS TT
∆H ∆T
∆T C = ∆T
TT TS
H H
TS = Stream supply temperature (oC)

TT = Stream target temperature (oC)
H = Stream enthalpy (MW)
C = m  ⋅ Cp (MW/ oC)
= Heat-capacity flow rate (MW/ oC)
= Stream flow rate × specific heat capacity 22
HEX REPRESENTATION IN Q-T DIAGRAMS
100
80o
Temperature
80
100o 60o 60
10o
∆Tmin = 10o ∆H
40
50o 0
Enthalpy
(a)
100
70o
Temperature
80
100o 60o
60
∆Tmin = 20o 20o
∆H 23
40
40o (b) 0
Enthalpy
Heuristics: Heat exchangers and furnaces
24 CHE 165 – Plant Design; D. Wagner
25. Unless required as part of the design of the separator or reactor, provide
necessary heat exchange for heating or cooling process fluid streams,
with or without utilities, in an external shell-and-tube heat exchanger
using countercurrent flow. However, if a process stream requires heating
above 750∘F, use a furnace unless the process fluid is subject to chemical
decomposition.
26. Near-optimal minimum temperature approaches in heat exchangers
depend on the temperature level as follows:
 10∘F or less for temperatures below ambient.
 20∘F for temperatures at or above ambient up to 300∘F.
 50∘F for high temperatures.
 250 to 350∘F in a furnace for flue gas temperature above inlet process fluid
temperature.
Adapted from SSLW

100
80o
Temperature
80
100o 60o 60
10o
∆Tmin = 10o ∆H
40
50o 0
Enthalpy
(a)
100
70o
Temperature
80
100o 60o
60
∆Tmin = 20o 20o
∆H 25
40
40o (b) 0
Enthalpy
100
80o
Temperature
80
100o 60o 60
10o
∆Tmin = 10o ∆H
40
50o 0
Enthalpy
100
80o
Temperature
80
100o 60o 60
10o
∆Tmin = 10o ∆H 26
40
50o 0
Enthalpy
100
80o
Temperature
80
100o 60o 60
10o
∆Tmin = 10o ∆H
40
50o 0
Enthalpy
80o
100
Temperature
H
67.5o 80
70o
100o C 60o 60 20o
∆Tmin = 20o QH
∆H - QH
QC
27
40
50o 0
Enthalpy
DEFINITIONS 70o
Exchanger Duty. 100o 60o

Data: Hot stream CH = 0.3 MW/ oC ∆Tmin = 20o
Cold stream CC = 0.4 MW/ oC 40o
Check: T1 = 40 + (100 - 60)(0.3/0.4) = 70oC 
Q = 0.4(70 - 40) = 0.3(100 - 60) = 12 MW
Heat Transfer Area (A): A = Q/(U⋅∆Tlm)

Data: Overall heat transfer coefficient, U=1.7 kW/m2 oC
(Alternative formulation in terms of film coefficients)
∆Tlm = (30 - 20)/loge(30/20) = 24.66
So, A = Q/(U⋅∆Tlm) = 12000/(1.7×24.66) = 286.2 m2

28
EXAMPLE PROBLEM
∆ H = 160
o
60 C
TS TT ∆H C
∆ H = 100 Stream (oC) (oC) (kW) (kW/oC)
o
80 C H1 180 80 100 1.0
180 oC H2 130 40 180 2.0
C1 60 100 160 4.0
C2 30 120 162 1.8
C-1
R-1
∆Tmin = 10 oC.
o
100 oC
120 oC Utilities. Steam@150 oC, CW@25oC
130 C
∆ H = 162 Design a network of steam heaters,

water coolers and exchangers for the
∆ H = 180 process streams. Where possible, use
exchangers in preference to utilities.
29
40 oC 30 oC
POSSIBLE SOLUTION TO EXAMPLE PROBLEM
60 oC
100 Summary of proposed design:

80 oC
180 oC
Steam CW Units
C-1 H 60 kW 18 kW 4
60 R-1
Are 60 kW of Steam
100 oC
130 oC
120 oC Necessary?
162
C
18
30
40 oC 30 oC
MER TARGETING WITH COMPOSITE CURVE
Example: TS TT ∆H C
Stream (oC) (oC) (kW) (kW/oC)
H1 180 80 100 1.0
H2 130 40 180 2.0
C1 60 100 160 4.0
C2 30 120 162 1.8
∆Tmin = 10 oC.
Tstart Tend ∆T CP ∆H
H1
H2
C1
C2
Interval
(oC) (oC) (oC) (kW/oC) (kW)
31
H1 180 80 100 1.0
H2 130 40 180 2.0
C1 60 100 160 4.0
C2 30 120 162 1.8
∆Tmin = 10 oC.
H1
H2
C1
C2
Interval
Cold-1 120 100 20 1.8 36
32
H1 180 80 100 1.0
H2 130 40 180 2.0
C1 60 100 160 4.0
C2 30 120 162 1.8
∆Tmin = 10 oC.
H1
H2
C1
C2
Interval
Cold-1 120 100 20 1.8 36
Cold-2 100 60 40 5.8 232
33
H1 180 80 100 1.0
H2 130 40 180 2.0
C1 60 100 160 4.0
C2 30 120 162 1.8
∆Tmin = 10 oC.
H1
H2
C1
C2
Interval
Cold-1 120 100 20 1.8 36
Cold-2 100 60 40 5.8 232
Cold-3 60 30 30 1.8 54
34
H1 180 80 100 1.0
H2 130 40 180 2.0
C1 60 100 160 4.0
C2 30 120 162 1.8
∆Tmin = 10 oC.
H1
H2
C1
C2
Interval
Cold-1 120 100 20 1.8 36
Cold-2 100 60 40 5.8 232
Cold-3 60 30 30 1.8 54
Hot-1 180 130 50 1.0 50
35
H1 180 80 100 1.0
H2 130 40 180 2.0
C1 60 100 160 4.0
C2 30 120 162 1.8
∆Tmin = 10 oC.
H1
H2
C1
C2
Interval
Cold-1 120 100 20 1.8 36
Cold-2 100 60 40 5.8 232
Cold-3 60 30 30 1.8 54
Hot-1 180 130 50 1.0 50
Hot-2 130 80 50 3.0 150 36
H1 180 80 100 1.0
H2 130 40 180 2.0
C1 60 100 160 4.0
C2 30 120 162 1.8
∆Tmin = 10 oC.
H1
H2
C1
C2
Interval
Cold-1 120 100 20 1.8 36
Cold-2 100 60 40 5.8 232
Cold-3 60 30 30 1.8 54
Hot-1 180 130 50 1.0 50
Hot-2 130 80 50 3.0 150 37
Hot-3 80 40 40 2.0 80
Int Tstart Tend ∆T CP ∆H
Cold-1 120 100 20 1.8 36
180
Cold-2 100 60 40 5.8 232
160 Cold-3 60 30 30 1.8 54
Hot-1 180 130 50 1.0 50

140
Hot-2 130 80 50 3.0 150
Temperature (oC) 120 Hot-3 80 40 40 2.0 80
100
80
60
40
20
0
0 50 100 150 200 250 300 350
Enthalpy (kW) 38
180
160
140
Temperature (oC) 120
100
80
60
40
20
0
0 50 100 150 200 250 300 350
Enthalpy (kW) 39
30 kW
180
160
140
100
“Pinch”
80
60
40
20
0
0 50 100 150 200 250 300 350
Enthalpy (kW) 40
100 kW
180
160
140

∆Tmin = 30o
100
80
60
40
20
0
0 50 100 150 200 250 300 350
Enthalpy (kW) 41
MER Targeting (∆Tmin = 20oC):
54 kW Hot pinch temperature = 80oC
180 Cold pinch temperature = 60oC
160
QH,min = 54 kW
QC,min = 12 kW
140
100 ∆Tmin = 20o
80
60
40
20
12 kW
0
0 50 100 150 200 250 300 350
Enthalpy (kW) 42
MER Targeting (∆Tmin = 10oC):
48 kW Hot pinch temperature = 70oC
180 Cold pinch temperature = 60oC
160
QH,min = 48 kW
QC,min = 6 kW
140
∆Tmin = 10o
100
80
60
40
20
6 kW
0
0 50 100 150 200 250 300 350
Enthalpy (kW) 43
MER TARGETING USING THE TI METHOD
The temperature-interval method (Linnhoff and Flower, 1978), a
systematic procedure for determining the minimum utility
requirements over all possible HENs, consists of the following steps:
 Adjusting the hot and cold stream temperatures to bring them to
the same reference.
 Determining the temperature intervals and carrying out enthalpy
balances in each interval.
 Computing the enthalpy cascade, the residual enthalpy flows,
determining the location of the "pinch," and computing MER
targets.
44
MER TARGETING WITH TI : EXAMPLE PROBLEM
∆ H = 160
o
60 C
TS TT ∆H C
o
80 C H1 180 80 100 1.0
180 oC H2 130 40 180 2.0
C1 60 100 160 4.0
C2 30 120 162 1.8
C-1
R-1
∆Tmin = 10oC.
100 oC
120 oC
130 oC
Utilities. Steam@150oC, CW@25oC
∆ H = 162
Compute the MER targets for this
∆ H = 180 process using the TI Method.
45
40 oC 30 oC
MER TARGETING WITH TI : STEP 1
 Adjusting the hot and cold stream temperatures to bring
them to the same reference.
o Need to adjust temperatures so that both hot and cold streams
are on the same terms of reference for a given desired ∆Tmin.
Arbitrarily, this is accomplished by subtracting ∆Tmin from all hot
stream temperatures.
Original stream table Adjusted stream table

TS TT ∆H C TS TT
Stream (oC) (oC) (kW/oC) Stream (oC)
(kW) (oC)
H1 180 80 100 1.0 H1 170 70
H2 130 40 180 2.0 H2 120 30
C1 60 100 160 4.0 C1 60 100
C2 30 120 162 1.8 C2 30 120
46
TS TT ∆H C
 Determining the temperature Stream (oC) (oC) (kW) (kW/oC)
intervals and carrying out H1 170 70 100 1.0
enthalpy balances in each H2 120 30 180 2.0
C1 60 100 160 4.0
interval. C2 30 120 162 1.8
∆H
Interval Ti-1 –Ti (oC) H1 H2 C1 C2 ΣCh –ΣCc (kW/oC)
(kW)
1
2
3
4
5
47
 Determining the temperature
intervals and carrying out
enthalpy balances in each
interval.
∆H
(kW)
1 170 – 120 = 50
2 120 – 100 = 20
3 100 – 70 = 30
4 70 – 60 = 10
5 60 – 30 = 30
TS TT ∆H C
H1 170 70 100 1.0 48
H2 120 30 180 2.0
C1 60 100 160 4.0
C2 30 120 162 1.8
TS TT ∆H C
C1 60 100 160 4.0
interval. C2 30 120 162 1.8
∆H
(kW)
1 170 – 120 = 50
2 120 – 100 = 20
3 100 – 70 = 30
4 70 – 60 = 10
5 60 – 30 = 30
49
TS TT ∆H C
C1 60 100 160 4.0
interval. C2 30 120 162 1.8
∆H
(kW)
1 170 – 120 = 50
2 120 – 100 = 20
3 100 – 70 = 30
4 70 – 60 = 10
5 60 – 30 = 30
50
TS TT ∆H C
C1 60 100 160 4.0
interval. C2 30 120 162 1.8
∆H
(kW)
1 170 – 120 = 50
2 120 – 100 = 20
3 100 – 70 = 30
4 70 – 60 = 10
5 60 – 30 = 30
51
TS TT ∆H C
C1 60 100 160 4.0
interval. C2 30 120 162 1.8
∆H
(kW)
1 170 – 120 = 50
2 120 – 100 = 20
3 100 – 70 = 30
4 70 – 60 = 10
5 60 – 30 = 30
52
TS TT ∆H C
C1 60 100 160 4.0
interval. C2 30 120 162 1.8
∆H
(kW)
1 170 – 120 = 50 1 50
2 120 – 100 = 20
3 100 – 70 = 30
4 70 – 60 = 10
5 60 – 30 = 30
53
TS TT ∆H C
C1 60 100 160 4.0
interval. C2 30 120 162 1.8
∆H
(kW)
1 170 – 120 = 50 1 50
2 120 – 100 = 20 1 + 2 –1.8 = 1.2 24
3 100 – 70 = 30
4 70 – 60 = 10
5 60 – 30 = 30
54
TS TT ∆H C
C1 60 100 160 4.0
interval. C2 30 120 162 1.8
∆H
(kW)
1 170 – 120 = 50 1 50
2 120 – 100 = 20 1 + 2 –1.8 = 1.2 24
3 100 – 70 = 30 1 + 2 –1.8 –4 = –2.8 –84
4 70 – 60 = 10 2 –1.8 –4 = –3.8 –38
5 60 – 30 = 30 2 –1.8 = 0.2 6
55
Energy Flows Between
Intervals (kW)
 Computing the First
enthalpy cascade, Pass
the residual enthalpy T0 = 170 oC QH R0 = 0
flows, determining
50
the location of the
"pinch," and T1 = 120 oC R1 = 50
computing MER 24
targets. R2 =74
T2 = 100 oC
-84
T3 = 70 oC R3 =-10
-38
T4 = 60 oC R4 =-48
6
56
T5 = 30 oC QC R5 =-42
Energy Flows Between
Intervals (kW)
 Computing the First Final
enthalpy cascade, Pass Pass
the residual enthalpy T0 = 170 oC QH R0 = 0 48 QHmin

flows, determining
50
the location of the
"pinch," and T1 = 120 oC R1 = 50 98
computing MER 24
targets. R2 =74 122
T2 = 100 oC
-84
No heat
T3 = 70 oC R3 =-10 38 transfers
across the
-38
MER Targeting:
pinch
T4 = 60 oC R4 =-48 0
Cold pinch temp. = 60oC
Hot pinch temp. = 70oC 6
57
QH,min = 48 kW
QC,min = 6 kW QCmin
T5 = 30 oC QC R5 =-42 6
PINCH DECOMPOSITION
58
THE SIGNIFICANCE OF THE PINCH
QHmin QHmin
T Heat sink
Pinch
Pinch
Heat source
QCmin
QCmin H
The “pinch” separates the HEN problem into two
parts:
 Heat sink - above the pinch, where at least QHmin
utility must be used.
 Heat source - below the pinch, where at least QCmin 59
utility must be used.
 At MER no heat passes across the pinch.
HEN DESIGN RULES FOR MER
 MER Targeting. Define pinch temperatures, QHmin
and QCmin.
 Divide problem at the pinch.
 Design hot-end, starting at the pinch: Immediately
above the pinch, pair up streams such that: CH ≤ CC.
“Tick off” streams to minimize costs. Add heating
utilities as needed (up to QHmin). Do not use cold
utilities above the pinch.
 Design cold-end, starting at the pinch: Immediately
below the pinch, pair up streams such that: CH ≥ CC.
“Tick off” streams to minimize costs. Add cooling
utilities as needed (up to QCmin). Do not use hot
utilities below the pinch. 60
 Done!
EXAMPLE MER SOLUTION: PROBLEM STATEMENT
∆ H = 160
o
60 C
TS TT ∆H C
o
80 C H1 180 80 100 1.0
180 oC H2 130 40 180 2.0
C1 60 100 160 4.0
C2 30 120 162 1.8
C-1
R-1
∆Tmin = 10oC.
o
100 oC
120 oC Utilities. Steam@150oC, CW@25oC
130 C
∆ H = 162 Design a network of steam heaters,

water coolers and exchangers for the
∆ H = 180 process streams. Where possible, use
exchangers in preference to utilities.
61
40 oC 30 oC
EXAMPLE MER SOLUTION – STEP 1
 MER Targeting.
C (kW/ oC)
180oC 80oC 1.0
H1
130oC 40oC
H2 2.0
100oC 60oC 4.0

C1
o 30oC 1.8 62
120 C C2
 MER Targeting. For ∆Tmin = 10oC:
Pinch temperatures 70oC and 60oC,
QH,min = 48 kW and QC,min = 6 kW
C (kW/ oC)
180oC 80oC 1.0
H1
130oC 40oC
H2 2.0
100oC 60oC 4.0

C1
o 30oC 1.8 63
120 C C2
QH,min = 48 kW QC,min = 6 kW
 Divide problem at the pinch.
C (kW/ oC)
180oC 80oC
H1 1.0
130oC 70oC 40oC

H2 2.0
100oC 60oC 4.0

C1
60oC 30oC 1.8

o
120 C C2 64
EXAMPLE MER SOLUTION – side
On hot STEP 3
@ pinch:
Pairing rule
 Design hot-end, is
starting at the pinch: Immediately above
CH ≤up
the pinch, pair CCstreams such
Th,out –that:
Tc,in C=H∆T CC. “Tick off”
≤ min
streams to minimize costs. Add heating utilities as needed
(up to QHmin). Do not use cold utilities above the pinch.
pinch
C (kW/ oC)
180oC 80oC
H1 1.0
130oC 70oC 40oC

H2 1 2.0
100oC 60oC 4.0

C1
60oC 30oC 1.8

o
120 C 1 C2 65
On hot STEP 3
@ pinch:
Pairing rule
CH ≤up
Th,out –that:
≤ min
pinch
C (kW/ oC)
180oC 80oC
H1 1.0
H2
130oC  1
70oC 40oC
2.0
100oC 60oC 4.0

1 C1
120
60oC 30oC 1.8

o
120 C C2 66
On hot STEP 3
@ pinch:
Pairing rule
CH ≤up
Th,out –that:
≤ min
pinch
C (kW/ oC)
H1
180oC  2
80oC
1.0
H2
130oC  1
70oC 40oC
2.0
100oC 60oC 4.0

1 C1
120
60oC 30oC 1.8

o
120 C 2 C2 67
100
 Design hot-end, starting at the pinch: Immediately above
the pinch, pair up streams such that: CH ≤ CC. “Tick off”
C (kW/ oC)
H1
180oC  2
80oC
1.0
H2
130oC  1
70oC 40oC
2.0
100oC  H 1 60oC C1 4.0
40 120
o
120 C 
H 2
60oC 30oC
C2 1.8 68
8 100
QH,min = 48 kW  QC,min = 6 kW
EXAMPLE MER SOLUTION – Sside
On cold TEP@4pinch:
 Design cold-end, starting at the pinch: Immediately below
the pinch,Tpair up streams such Pairing
h,in – Tc,out = ∆Tmin
that: Crule
H ≥ CisC. “Tick off”
streams to minimize costs. Add cooling CH ≥ utilities
CC as needed
(up to QCmin). Do not use pinch hot utilities below the pinch.
C (kW/ oC)
H1
180oC  2
80oC
1.0
H2
130oC  1
70oC
3
40oC
2.0
100oC  H 1 60oC C1 4.0
40 120
o
120 C 
H 2
60oC
3  30oC
C2 1.8 69
8 100 54
QH,min = 48 kW  QC,min = 6 kW
 Design cold-end, starting at the pinch: Immediately below
the pinch, pair up streams such that: CH ≥ CC. “Tick off”
streams to minimize costs. Add cooling utilities as needed
(up to QCmin). Do not use hot utilities below the pinch.
C (kW/ oC)
H1
180oC  2
80oC
1.0
H2
130oC  1
70oC
3 C  40oC
2.0
100oC  H 1 60oC C1 4.0
40 120
o
120 C 
H 2
60oC
3  30oC
C2 1.8 70
8 100 54
QH,min = 48 kW  QC,min = 6 kW 
PREVIOUS SOLUTION TO EXAMPLE PROBLEM
60 oC
80 oC 100
Summary of previous design:
180 oC
Steam CW Units
C-1 H 60 kW 18 kW 4
60 R-1
Are 60 kW of Steam
100 oC
120 oC
Necessary?
130 oC
162
C
18
71
40 oC 30 oC
MER SOLUTION TO EXAMPLE PROBLEM
60 oC
80 oC 100
Summary of MER design:
180 oC
Steam CW Units
C-1 H 48 kW 6 kW 6
60 R-1
100 oC
120 oC
130 oC
162
C
18
72
40 oC 30 oC
MER SOLUTION TO EXAMPLE PROBLEM
60 oC
80 oC 100
180 oC
Summary of MER design:
120
Steam CW Units
C-1
48 kW 6 kW 6
R-1
H
40
100 oC
o
120 oC
130 C
H
8
54
C
6
73
40 oC 30 oC
Capital Targets
• How do we get the capital cost without designing the
heat exchange network (HEN)?
Qhot
Temperature
Qcold Qrec
Duty
Thermodynamic Significance of the Pinch
“pinch”
Temperature Qhot min
Qrec max
Qcold min
Duty
• When the process is pinched it is

decomposed into two sub problems
Pinch Decomposition
Above the pinch
we only put in
“pinch”
Qhot min utility heat and
the process acts
Temperature
as a heat sink
Below the pinch we

only reject heat to cold
Qrec max utility and the process
Qcold min acts as a heat source
Duty
• When the process is pinched it is

decomposed into two sub problems
Pinch Decomposition
• What if we put in extra heat above the pinch?
Qextra
“pinch”
Qhot min
Temperature
Qextra Heat sink is now out

of energy balance
and we have to
reject Qextra to a
lower temperature
Qrec max
Qcold min
Duty

Pinch Decomposition
• What if we put in extra heat above the pinch?
Qextra
“pinch”
Qhot min
Temperature
Qextra
Now the heat
source is also out of
Qextra energy balance and
we have to reject
Qrec max
Qcold min Qextra to cold utility
Duty

Pinch Decomposition
The overall effect is that both hot and cold utility are increased by
the amount of heat transferred across the pinch = Qextra
Qextra
“pinch”
Qhot min
Temperature
Qextra
Qextra
Qrec max
Qcold min
Duty
So a simple rule for achieving energy targets is don’t
transfer heat across the pinch!
Pinch Design Method
• Use composite curves to find the pinch temperature
• Optimize ∆Tmin, making process changes
• Decompose the network design problem using the pinch

temperatures
• Design the Heat Exchanger Network (HEN) for each

subsystem separately:
– Transfer no heat “across” the pinch
– ∆T > ∆Tmin for all heat exchangers
– Start at the pinch and work outward

Pinch Analysis: Overall Conclusions
• The pinch techniques can give useful insights into process energy efficiency
• The main value lies in identifying good process modifications and choosing
the right utilities
• It is seldom (if ever) necessary to work through all of the details of the
analysis – most benefit is gained with a high-level view
• Different techniques are used for retrofit of existing networks and these can
have more value, particularly in petrochemicals


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CHE 165 – Plant Design; D.

Heat Exchange Networks (HENs)

Heat Integration Schematics

• How can we determine the optimal values for

© 2012 G.P. Towler / UOP. For educational use in conjunction with

© 2012 G.P. Towler / UOP. For educational use in conjunction with

• What is ∆Tlm for the process-process exchanger?

• How big is the process-process heat exchanger?

© 2012 G.P. Towler / UOP. For educational use in conjunction with

• How can we find an optimum ∆Tmin?

– Combine capital and operating costs to determine

Cost (10 $/y)

Utility Costs Annualized Capital Cost

© 2012 G.P. Towler / UOP. For educational use in conjunction with

• Stream data must be combined in such a way as to represent

• The pinch method creates what is called a composite curve.

© 2012 G.P. Towler / UOP. For educational use in conjunction with

Streams A and B have overlapping duties between 520° and 550°.

© 2012 G.P. Towler / UOP. For educational use in conjunction with

Plot T vs. Q for each temperature range.

© 2012 G.P. Towler / UOP. For educational use in conjunction with

© 2012 G.P. Towler / UOP. For educational use in conjunction with

© 2012 G.P. Towler / UOP. For educational use in conjunction with

© 2012 G.P. Towler / UOP. For educational use in conjunction with

• We can set targets

© 2012 G.P. Towler / UOP. For educational use in conjunction with

• Since the duty scale

© 2012 G.P. Towler / UOP. For educational use in conjunction with

600 Pinch • If we decrease ΔTmin

© 2012 G.P. Towler / UOP. For educational use in conjunction with

– More utilities are consumed

• How do we decide on the appropriate ∆Tmin?

Utility Costs Annualized Capital Cost

© 2012 G.P. Towler / UOP. For educational use in conjunction with

• In practice, energy prices are affected by:

• So the actual energy price varies with time and is

© 2012 G.P. Towler / UOP. For educational use in conjunction with

TS = Stream supply temperature (oC)

Adapted from SSLW

Exchanger Duty. 100o 60o

Check: T1 = 40 + (100 - 60)(0.3/0.4) = 70oC 

Q = 0.4(70 - 40) = 0.3(100 - 60) = 12 MW

Heat Transfer Area (A): A = Q/(U⋅∆Tlm)

So, A = Q/(U⋅∆Tlm) = 12000/(1.7×24.66) = 286.2 m2

∆ H = 162 Design a network of steam heaters,

100 Summary of proposed design:

160 Cold-3 60 30 30 1.8 54

Hot-1 180 130 50 1.0 50

Temperature (oC) 120 Hot-3 80 40 40 2.0 80

Temperature (oC) 120

Temperature (oC) 120

Temperature (oC) 120

Temperature (oC) 120

100 ∆Tmin = 20o

Temperature (oC) 120

Original stream table Adjusted stream table

the residual enthalpy T0 = 170 oC QH R0 = 0

the residual enthalpy T0 = 170 oC QH R0 = 0 48 QHmin