30/07/2013

Lecture Content

Problem Table Algorithm (PTA)
– Shifted temperature
CHE 4173 Sustainable Processing II – Energy balance
Heat Exchanger Network – PTA & GCC – Heat cascade

Grand Composite Curve (GCC)
– Utility selection
– Steam generation with GCC

Dr. Irene Chew

Sunway Campus

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The composite curves QHmin

Its limitation & alternative
T (ºC)
Limitation of composite curves
– Graphical construction – inconvenient
– Inaccuracy
Pinch – Computational ineffective
Heat
sink – Software interaction is limited
Heat
source

Another targeting tool – the problem table algorithm (PTA)
∆Tmin
– Numerical alternative to locate energy targets
– Accurate and rapid

H (MW)
QCmin

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The Tbasic principles of PTA Calculation steps

1.
H 2.

Shift the temperature according toTmin:
– Hot composite is shifted ∆Tmin/2 colder than it is in practice
– Cold composite is shifted ∆Tmin/2 hotter than it is in practice

The shifted composite curves will touch at the pinch

Note: shifting is just for the sake of PTA calculation, no actual shifting!
3.
Set up shifted temperature intervals from original stream TS & TT
values:
– Hot stream: subtract ∆Tmin/2 to make it colder
– Cold stream: add ∆Tmin/2 to make it hotter
Calculate energy balance in each shifted temperature intervals i:
– If hot stream dominate: ∆H in +ve  heat surplus
– If cold stream dominate: ∆H in -ve  heat deficit
Cascade the heat down the temperature interval, provide external
hot utility if needed

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Back to the previous example PTA Step 1 – Shifted T intervals

Feed 2 230ºC 200ºC Product 2
Reactor 2
Set up shifted temperature intervals from original stream
140ºC 80ºC
Feed 1 180ºC TS & TT values:
250ºC
Reactor 1 Off gas, 40ºC
– Hot stream: subtract ∆Tmin/2 to make it colder
20ºC
– Cold stream: add ∆Tmin/2 to make it hotter
40ºC

∆Tmin = 10 ºC
Product 1, 40ºC

Stream Type TS TT T *S T*T

Supply temp, Target temp, DH Heat capacity
Steam Type flowrate, CP C1 Cold 20 180 25 185
TS (ºC) TT (ºC) (MW) (MW.K-1)
1. Reactor 1 feed Cold 20 180 32.0 0.20 H2 Hot 250 40 245 35
2. Reactor 1 product Hot 250 40 –31.5 0.15
C3 Cold 140 230 145 235
3. Reactor 2 feed Cold 140 230 27.0 0.30
4. Reactor 2 product Hot 200 80 –30.0 0.25 H4 Hot 200 80 195 75

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PTA Step 1 – Shifted T intervals PTA Step 2 – ∆H balance

Shift temp Surplus/D
T* (ºC) Stream population ∆T* ΣCPH - ΣCPC ∆H
interval, T* (ºC) eficit
H2 H2
245 245
10 0.15 1.5 Surplus
235 235
H4 H4 40 -0.15 -6.0 Deficit
195 195
CP = 0.3

10 0.1 1.0 Surplus

CP = 0.25
CP = 0.15

185 185
40 -0.1 -4.0 Deficit
145 145
C3 C3 70 0.2 14.0 Surplus
CP = 0.2

75
75
40 -0.05 -2.0 Deficit
35 35
10 -0.2 -2.0 Deficit
25
25 C1
C1

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PTA Step 3 – Heat cascade QHmin = Convention of ∆H in Step 2

Hot utility Hot utility
245 0 MW 245 7.5 MW
∆H = 1.5 ∆H = 1.5

Conventional Process Integration books (Linnhoff et al.,
235 1.5 MW Negative heat 235 9.0 MW 1982; Smith, 1995, 2005) follow standard thermodynamics
∆H = -6.0 cascade – ∆H = -6.0 convention
195 -4.5 MW infeasible (heat is 195 3.0 MW

Energy balance calculation in Step 2:
∆H = 1.0 transferred from ∆H = 1.0
185 -3.5 MW lower to higher 185 4.0 MW
∆H = -4.0 temp) ∆H = -4.0
145 -7.5 MW 145 0 MW
– If cold stream dominate: ∆H in -ve  heat deficit
∆H = 14.0 ∆H = 14.0
75 6.5 MW 75 14 MW
– If hot stream dominate: ∆H in +ve  heat surplus
∆H = -2.0 Largest heat ∆H = -2.0
35 4.5 MW deficit 35 12.0 MW

Consistent with ∆HR of exothermic reaction in positive value
∆H = -2.0
Pinch temp:
∆H = -2.0 QCmin =
25 2.5 MW 25 10.0 MW
All calculation steps remain the same
Hot stream = 145+5 = 150ºC
Cold utility Cold stream = 145–5 =140ºC Cold utility

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Overall heat cascading Composite curves

QHmin = 7.5

QCmin = 10

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Match values obtained from CC Working session

T (ºC)
Calculate the hot & cold utility requirements and the pinch
location
250
230
Assuming ∆Tmin = 5ºC
Pinch

∆Tmin = 10ºC

40
20

H (MW)
QCmin = 10 QREC = 51.1 QHmin = 7.5

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Data extraction Step 1 - T* interval construction

CP
Stream Type TS (ºC) TT (ºC) DH (MW) Stream Type CP TS TT T *S T*T
(MW/K)
1. Feed to column 1 H 20 0 -0.8 0.04 1 H 0.04 20 0 17.5 -2.5

2. Column 1 condenser H 1.2 2 H 1.2

3 H 0.8
3. Column 2 condenser H 0.8
4 C 1.2
4. Column 1 reboiler C 1.2
5 C 0.8
5. Column 2 reboiler C 0.8
6 C 0.01
6. Column 2 bottoms C 0.01
7 C 0.01 -40 20 -37.5 22.5
7. Column 2 overheads C -40 20 0.6 0.01

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PTA Step 2 – ∆H balance PTA Step 3 – Heat cascade

T* Stream population Surplus/ Hot utility Hot utility
QHmin = _____ MW
∆T * ∑CPH - ∑CPC ∆H 22.5 0 22.5
(ºC) H1 H2 H3 C4 C5 C6 C7 Deficit -1.22 -1.22
21.5 -1.22 21.5
22.5 -0.08 -0.08
1 -1.22 -1.22 D 17.5 -1.30 17.5
21.5
4 -0.02 -0.08 D 0.30 0.30
17.5 2.5 -1.00 2.5
15 0.02 0.30 S
2.5 1.5 1.5
1 -0.77 D
1.5 -2.5 -2.5
4 0.12 S
-2.5
-21.5 -1.84 -21.5 0 (PINCH)
19 -0.19 D
-21.5
1 1.19 S -22.5 -22.5
-22.5
15 -0.15 D -37.5 -37.5
-37.5
4 0 --- -41.5 -41.5
-41.5
1 0.8 S
-42.5 -42.5 -42.5
Cold utility Cold utility QCmin = _____ MW
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Heat Exchanger Network (HEN) to In conventional PDF

achieve the targets

Network design is not our concern now,

we will learn how to design the network
later

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The “Onion diagram” Hot Utility Systems

Steam system

Reactor

Separation &
recycle
Heat exchanger
network We are finally
Hot oil system
here
(Linnhoff et al., 1982; Smith, Utilities
1995, 2005)

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Cold utility systems Back to the previous example

Feed 2 230ºC 200ºC Product 2
Reactor 2
140ºC 80ºC
Cooling water Feed 1 180ºC
250ºC
Reactor 1 Off gas, 40ºC
system 20ºC

40ºC

Product 1, 40ºC
Target Heat capacity
Supply temp, DH
Steam Type temp, flowrate, CP
TS (ºC) (MW) (MW.K-1)
TT (ºC)
1. Reactor 1 feed Cold 20 180 32.0 0.20
Refrigeration 2. Reactor 1 product Hot 250 40 –31.5 0.15
system 3. Reactor 2 feed Cold 140 230 27.0 0.30
4. Reactor 2 product Hot 200 80 –30.0 0.25
Note: Heat capacity flowrate, CP = m.Cp

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GCC Hot utility Grand composite curve (GCC)

Shift temp, T * (ºC)
245 7.5 MW Shift temp,
∆H = 1.5 T * (ºC)
Excess hot streams
235 9.0 MW
∆H = -6.0
195 3.0 MW QHmin = 7.5 MW Heat sink
∆H = 1.0 Excess cold streams
185 4.0 MW
∆H = -4.0
145 0 MW Pinch 145 Pinch
∆H = 14.0 Heat
source
75 14 MW
∆H = -2.0

35 12.0 MW
∆H = -2.0
25 10.0 MW QCmin = 10 MW
Cold utility
H (MW)
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Utility selection (pg. 373, Smith) Utility selection

Hot utility

For 2 levels of steam @ saturated condition & temperature 245 7.5 MW
of 240º & 180ºC, determine the loads on the 2 stream levels ∆H = 1.5
that maximises the use of lower pressure steam. 235 9.0 MW
∆H = -6.0
195 3.0 MW
∆H = 1.0
185 4.0 MW
∆H = -4.0
145 0 MW
∆H = 14.0

75 14 MW
∆H = -2.0
35 12.0 MW
∆H = -2.0
25 10.0 MW
Cold utility

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Solution : Utility selection

For ∆Tmin = 10oC, the two steam levels are plotted on the
Instead of using steam, a hot oil circuit is to be used with a
GCC at 235oC and 175oC. supply temperature of 280ºC & CP = 2.1 kJ/kg.K. Calculate
the minimum flowrate of hot oil.

The load of low pressure steam is calculated by interpolation
on the cascade heat flows.

Load of 180oC steam : Which slope correspond

to the lowest flowrate?

Load of 240oC steam:

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Steam generation Utilities for Furnaces (Read pg. 374, Smith)

How much low pressure steam @ 120ºC may be generated
by exploring the use of the rejected heat? [Ans: ~4.2 MW].
Theoretical Flame Temperature (TFT) =
temperature attained when fuel is burnt in
air/oxygen without loss/gain of heat
Stack temperature = temperature where
flue gas is released
Stack loss = Heat released from flue gas
between pinch temperature & ambient

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PTA (Tmin = 30 C) PTA (Tmin = 50C)

Surplus/ Surplus/
T * (ºC) Stream population ∆T * ∑CPH - ∑CPC ∆H T * (ºC) Stream population ∆T * ∑CPH - ∑CPC ∆H
Deficit Deficit

245 255
10 -0.3 -3.0 Deficit H2 30 -0.3 -9.0 Deficit
H2 225
235
40 -0.15 -6.0 Deficit 20 -0.15 -3.0 Deficit
CP = 0.3

195 205
CP = 0.3

10 -0.35 -3.5 Deficit 30 -0.35 -10.5 Deficit

H4 175 H4
185
CP = 0.15

CP = 0.25

30 -0.1 -3.0 Deficit 10 -0.1 -3.0 Deficit

CP = 0.15

CP = 0.2
CP = 0.2

165
CP = 0.25

155 C3 C3
90 0.2 18.0 Surplus 110 0.2 22.0 Surplus
65 55
30 -0.05 -1.5 Deficit 10 -0.05 -0.5 Deficit
35 45 C1
C1 10 0.15 1.5 Surplus 30 0.15 4.5 Surplus
25 15

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