Setting Energy Targets

ENGM071 - Process and Energy Integration

Outline
• Introduction to Pinch Technology
• Basic terminology of heat integration
• Driving forces in heat exchangers
• Setting energy targets

2
 Classification of Methods of
Process and Energy Integration
Qualitative
Rule-based approaches to Insight about design
handle qualitative (fuzzy) and economics
knowledge

Knowledge-based
Heuristic Rules
Systems

HIERARCHICAL
Automatic Interactive
ANALYSIS

Optimisation Thermodynamic
Methods Methods

Deterministic and stochastic Pinch Analysis and methods

methods of Mathematical with focus on
Programming Thermodynamics
Quantitative
3
 Classification of Methods of
Process and Energy Integration
Qualitative
Rule-based approaches to Insight about design
handle qualitative (fuzzy) and economics
knowledge

Knowledge-based
Heuristic Rules
Systems

HIERARCHICAL
Automatic Interactive
ANALYSIS

Optimisation Thermodynamic
Methods Methods

Deterministic and stochastic Pinch Analysis and methods

methods of Mathematical with focus on
Programming Thermodynamics
Quantitative
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Pinch Technology
“It is a methodology for minimising energy consumption of
processes by computing thermodynamically feasible energy
targets (for minimum energy consumption) and achieving them
by optimising heat recovery systems, energy supply methods and
process operating conditions”

• The most widely used PI methodology

• Based on thermodynamic principles
• Well-proven in industry (chemical, petrochemical, oil, paper and pulp,
food and drinks, metallurgy, etc.) leading to considerable savings:
• energy 10-35%
• water 25-40%
• hydrogen 20%
• …
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Key steps of Pinch Technology
There are four key steps of pinch analysis in the design of
heat recovery systems for both new and existing processes:

1. Data Extraction from a PFD, which involves collecting

data for the process and the utility system
2. Selection of Δ𝑇𝑚𝑖𝑛 (minimum approach temperature),
which establishes targets for design in terms of energy,
number of units, area, etc. for best performance
3. Design, where an initial HEN is established
4. Optimization, where the initial design is simplified and
improved economically

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Basic Terminology of Heat
Integration

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Laws of Thermodynamics
First law of thermodynamics
The increase in internal energy of a closed system is equal to
total of the energy added to the system

Work done
Δ𝑈 = 𝑄 − 𝑊 on system

+W
U
+Q -Q
Internal energy

Heat added -W Heat given off

to system by system
Work done by
the system
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Laws of Thermodynamics
Second law of thermodynamics
Indicates the irreversibility of natural processes, the tendency
to lead towards spatial homogeneity of matter and energy

Matter
Ordered Disordered
system system

Energy

High
temp. H E AT Low temp.

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Laws of Thermodynamics
Second law of thermodynamics: corollary

Disordered Ordered
system system

High
Low temp. H E AT
temp.

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Laws of Thermodynamics
Second law of thermodynamics: corollary
WORK

Disordered Ordered
system system

WORK

High
Low temp. H E AT
temp.

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Enthalpy
Enthalpy = total heat content of a system

We are only interested in enthalpy changes, Δ𝐻, as a result of

heat transfer
… occurring in heat exchangers (HE)

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Heat transfer
The amount of heat transferred in a counterflow HE can be written as
𝑄 = 𝑈 ∙ 𝐴 ∙ Δ𝑇𝐿𝑀
𝑈 – heat transfer coefficient
𝐴 – heat transfer area
Δ𝑇𝐿𝑀 – log-mean temperature difference (mean driving force!)
The amount of heat transferred is equal to the enthalpy change of a
stream
𝑄 = Δ𝐻
Assumptions:
• There is no phase change in the system
• Heat loss into the surroundings is negligible
• The process is at steady state
• Fluid properties and U are considered constant
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Stream Heat Balance
The heat available from a hot stream (or needed by a cold stream)
depends on its:
• supply temperature, 𝑇𝑠 (typically in °C or K)
• target temperature, 𝑇𝑇 (typically in °C or K)
• heat capacity flow rate, 𝐶𝑃 (in kW/°C or kJ/h °C):
𝐶𝑃 = 𝑚ሶ ∙ 𝐶𝑝
𝑚ሶ is the stream flowrate (kg/s or kg/h)
𝐶𝑝 its specific heat capacity (kJ/kg °C)

Therefore,
Δ𝐻 = 𝐶𝑃 ∙ Δ𝑇 = 𝐶𝑃 ∙ 𝑇𝑇 − 𝑇𝑆
NB: Δ𝐻 > 0 for cold streams (heat acceptors)
Δ𝐻 < 0 for hot streams (heat donors)
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Temperature-Enthalpy Diagrams
Consider two streams:
a hot one 240°C 40°C Δ𝐻 = 800 kW

and a cold one 80°C 205°C Δ𝐻 = 1000 kW

Δ𝐻 = 𝐶𝑃 ∙ Δ𝑇

Hot stream:
800 kW
𝐶𝑃𝐻 = =4
240 − 40 K

Col stream:
1000 kW
𝐶𝑃𝐶 = =8
205 − 80 K

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 Cooling the hot stream with CW
We could cool the hot stream with e.g. cooling water supplied at 20°C
and rejected at 60°C
𝑄
Let us estimate the required size of the HEX: 𝐴 =
𝑈∙Δ𝑇𝐿𝑀

240
The log-mean temperature difference
is given by
200
Δ𝑇𝐻 − Δ𝑇𝐶 180 − 20
Δ𝑇𝐿𝑀 = = = 72.8°𝐶
Δ𝑇𝐻 180
Temperature (°C)

160
Δ𝑇𝐻 = 180°𝐶 ln Δ𝑇 ln 20
𝐶
120
Assume that the overall heat transfer
80 coefficient, U, is 1 kW m-2 K-1.
40
Δ𝑇𝑐 = 20°𝐶
Then the required HEX area is:
0
𝑄 800
0 400 800 1200
𝐴= = = 10.99 m2
Heat Flow (kW) 𝑈 ∙ Δ𝑇𝐿𝑀 1 × 72.8
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 Heating the cold stream with steam
We could heat the cold stream with a hot utility, e.g. steam
condensing at 240°C
The log-mean temperature difference
is given by
240 160 − 35
Δ𝑇𝐿𝑀 = = 82.25°𝐶
Δ𝑇𝐻 = 35°𝐶 160
ln
200 35
Δ𝑇𝑐 = 160°𝐶

Temperature (°C)

160
The required area of a pure counter-
120
current heat exchanger is
80
𝑄 1000
𝐴= = = 12.16 m2
40 𝑈 ∙ Δ𝑇𝐿𝑀 1 × 82.25

0
0 400 800 1200
Heat Flow (kW)
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Let’s attempt some heat recovery…
We can plot both lines on the same graph!

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Let’s attempt some heat recovery…
We can plot both lines on the same graph!
We can move them horizontally since we are only interested in
enthalpy changes!

800 kW 1000 kW

No heat recovery. A total of 1800 kW of heat exchange 19

Let’s attempt some heat recovery…
We can’t cool the hot stream down to 40°C using a cold stream initially at 80°C!
Similarly, the hot stream can’t give 1000 kW to satisfy the requirements of the
cold stream

800 kW 1000 kW

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Let’s attempt some heat recovery…
We could, for example, cool the hot stream some of the way, say to 140°C
In thus cooling the hot stream would lose 400 kW to the cold stream
The cold stream would gain 400 kW and heat up by 50°C to 130°C

400 kW

kW
𝐶𝑃𝐻 = 4
K
kW
𝐶𝑃𝐶 = 8
K

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Let’s attempt some heat recovery…
We could, for example, cool the hot stream some of the way, say to 140°C
In thus cooling the hot stream would lose 400 kW to the cold stream
The cold stream would gain 400 kW and heat up by 50°C to 130°C

400 kW

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Let’s attempt some heat recovery…
For the rest of the cooling the hot stream would need to use cooling water
The rest of the heating of the cold stream up to 205°C would need 600 kW of
steam

400 kW 400 kW 600 kW

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What do we get?…
3 heat exchangers transferring 1400 kW of heat in total
…instead of 2 heat exchangers transferring 1800 kW

400 kW 400 kW 600 kW

HEAT
COOLING RECOVERY HEATING

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What about heat exchange area?

400 kW 400 kW 600 kW

Δ𝑇𝐿𝑀1 = 43.3°C Δ𝑇𝐿𝑀2 = 82.5°C Δ𝑇𝐿𝑀3 = 65.5°C

𝐴𝑡𝑜𝑡𝑎𝑙 = 9.24 + 4.85 + 9.16 = 23.25 m2

Similar to 𝐴𝑡𝑜𝑡𝑎𝑙 = 10.99 + 12.16 = 23.15 m2 initially 25

Conclusion
Running costs: Before After
QH 1000 kW 600 kW
QC 800 kW 400 kW

Note: more in – more out!

Heat recovery saves double the heat exchanged!

Capital costs: 3 heat exchangers will cost more than 2, even

though the total heat exchange area is approximately the same

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Setting Energy Targets

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Can we recover more?
Bring the lines together until they are touching, i.e. to the theoretical limit of
heat recovery of 640 kW!
Is it feasible?

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Can we recover more?
Bring the lines together until they are touching, i.e. to the theoretical limit of
heat recovery of 640 kW!
Is it feasible?

𝑑𝑄
𝑑𝐴 =
Δ𝑇 𝑈 ∙ Δ𝑇

Δ𝑇 → 0 ⟹ 𝑑𝐴 → ∞

⟹ Infinite heat transfer area!

⟹ Infinite cost of heat exchanger

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Minimum approach temperature, Δ𝑇𝑚𝑖𝑛
Set Δ𝑇𝑚𝑖𝑛 = 10°C

Δ𝑇 = 10°C

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Minimum approach temperature, Δ𝑇𝑚𝑖𝑛
Set Δ𝑇𝑚𝑖𝑛 = 10°C

𝑄𝐻𝑚𝑖𝑛 = 400 kW 𝑄𝐶𝑚𝑖𝑛 = 200 kW – Energy Targets!

200kW 600 kW 400 kW

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Increasing Δ𝑇𝑚𝑖𝑛
Set Δ𝑇𝑚𝑖𝑛 = 20°C

𝑄𝐻𝑚𝑖𝑛 = 440 kW 𝑄𝐶𝑚𝑖𝑛 = 240 kW

Energy Targets increase
with Δ𝑇𝑚𝑖𝑛

240kW 560 kW 440 kW

Minimum approach temperature, Δ𝑇𝑚𝑖𝑛 , determines

the maximum possible amount of heat recovery

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Heat exchanger network for Δ𝑇𝑚𝑖𝑛 = 20°C

240°C
240kW 560 kW 440 kW
80°C 560 150°C 205°C
H
kW
Δ𝑇𝑚𝑖𝑛
= 20°C 440 kW
100°C

C 240 kW

40°C

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Costs vs. Driving Force
Is a larger driving force better? – YES and NO!

𝑄
𝐴=
𝑈 ∙ Δ𝑇𝐿𝑀

Capital cost:
~𝐴𝛼
Operating cost:
~Δ𝑇𝐿𝑀

It’s a trade-off between capital and running costs!

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Summary
• Heat recovery saves energy by reducing the amount of both hot
and cold utility required
• Heat recovery reduces driving forces, so tends to increase the
size and capital cost of heat exchangers

• Minimum approach temperature, Δ𝑇𝑚𝑖𝑛 , determines the

maximum possible amount of heat recovery

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