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2.control and Process Integration
2.control and Process Integration
P&ID provides:
1.Information needed by engineers to begin planning for the
construction of the plant.
2.Every mechanical aspect of the plant except the information given in
Table 1.8.
3.Table 1.9 gives the general conventions used in drawing P&IDs.
4.Each PFD will require many P&IDs to provide the necessary data.
5.A numbered box in the PID identifies utility connections. The number
with within the box identifies the specific utility. The key identifying the
utility connections is shown in the table on the PID.
6.All process information that can be measured in the plant is shown
on the PID by circular flags, including the information to be recorded
and used in process control loops.
Table 1.8 Exclusions from Piping and Instrumentation Diagram
1.Mechanical engineers and civil engineers will design and install pieces
of equipment.
2.Instrumental engineers will specify, install and check control systems.
3.Piping engineers will develop plant layout and elevation drawings.
4.Project engineers will develop plant and construction schedules.
17
Process Integration
Objectives
The concept of pinch technology.
Composite curve
Problem table algorithm
Grand composite curve (utility target)
Heat exchanger network design
Pinch Technology
Pinch Technology refers to a simple methodology
for systematic analysis of chemical processes and
the surrounding system with the help of the first
and second laws of thermodynamics.
water
sterilizer
oven packing
Flour+ biscuits
sugar+
flavour
Heat
transferred
SOURCE SINK
The Basics
HOT STREAMS or HEAT SOURCE - streams that need
cooling
Heat
transferred
SOURCE SINK
1. Energy Balance
2. Design Equation
1. Energy Balance :
1. Design Equation
Q = UA DT LMTD
Introducing T-DH plot
T
T h1
T h1 T h2
Q
T c2
T h2
T c2 T c1
T c1
DH
Q
What if the external utility comes in..
T H
T h1
T h2 T h3
T h1 Th3
Q C
T c2
H T h2
Tc3 T c1 Tc3
T c2
T c1
C DH
Q
Remember your goal is to cut down the
energy bills
T H
T h1
T h2 T h3
T h1 Th3
Q C
T c2
H T h2
Tc3 T c1 Tc3
T c2
T c1
C DH
Q
How ?
Of course by more heat recovery
T H
T h1
T h2
T h1 Q C
T h3 Th3
T c2 DTmin
H T h2
Tc3 T c1 Tc3
T c2
T c1 Q
DH
C
Q
Is this possible?
Recall your basic thermodynamics matters
DTmin is the minimum T that should exist in order to allow any heat transfer.
What are the implications?
T H
T h1
T h2
T h1 Q C
T h3 Th3
T c2 DTmin
H T h2
Tc3 T c1 Tc3
T c2
T c1 Q
DH
C
Q
Positive or negative?
What are the implications?
T H
T h1
T h2
T h1 Q C
T h3 Th3
T c2 DTmin
H T h2
Tc3 T c1 Tc3
T c2
T c1 Q
DH
C Q
Positive: Energy consumption reduced
Negative: Area increased
What are the implications?
T H
T h1
T h2
T h1 Q C
T h3 Th3
T c2 DTmin
H T h2
Tc3 T c1 Tc3
T c2
T c1 Q
Area = Q DH
C Q
U DT
What if we want to use more energy?
T H
T h1
T h2
T h1 Q C
T h3 Th3
DTmin
T c2
H T h2
Tc3 T c1 Tc3
T c2
T c1 Q
Area = Q C Q
DH
U DT
250
200
25
=1
=
CP
CP
80
40
H (kW)
3150 3000
6150
Example 2: composite cold stream
230 230
30
30
=
=
CP
180
CP
180
140
0
140
50 3
= 20 +
20
20
=
=
CP
CP
CP
20 20
H (kW) H (kW)
3200 2700 3200 2700
5900 5900
Example 2: Composite curves
200
Pinch
DTmin = 10oC
80
40
H (kW)
250
200
Pinch
DTmin = 20oC
80
40
H (kW)
T T
1 2
(DTmin)1 = 10 C
(DTmin)2
H H
Cost
TOTAL
Energy
Capital
DTmin
1 2
Optimum
So far, generating the composite curves is complicated
and tedious
STEP 1:
DT min = 10oC
Product Hot 80 40 75 35
T* interval
temperature FCp (kW/oC)
3 2 1
125oC
105oC
75oC
35oC
25oC
STEP 3: In each shifted temperature interval, calculate
energy balance from:
T* interval
temperature FCp (kW/oC) SFCP -
DTinterval H DHinterval Surplus/
3 2 1 (oC)
SFCP C
o
(kW) deficit
125oC (kW/ C)
20 -1 -20 Deficit
105oC
30 -3 -90 Deficit
75oC
40 1 40 Surplus
35oC
10 -2 -20 Deficit
25oC
Surplus = excess heat available in the interval
Deficit = deficit heat in the interval
STEP 4: Cascade any surplus heat from high to low
temperature
T* interval
temperature FCp (kW/oC) HOT UTILITY
3 2 1 0 kW
125oC
-20
105oC 20 kW Deficit (D)
-90
75oC 110 kW Deficit (D)
40
35oC 70 kW Deficit (D)
-20
25oC 90 kW Deficit (D)
COLD UTILITY
..and find the MAXIMUM heat deficit
Use MAXIMUM heat deficit to cascade surplus
heat flows
T* interval
temperature FCp (kW/oC) HOT UTILITY
3 2 1 110 kW
125oC
-20
105oC 90 kW Surplus
-90
75oC 0 kW (PINCH)
40
35oC 40 kW Surplus
-20
25oC 20 kW Surplus
20 kW
T* pinch= 75oC
COLD UTILITY
T hot pinch = 80oC
T cold pinch = 70oC QH min = 110 kW, QC min= 20 kW
Summary for Problem Table Algorithm
HP Steam
STEAM TURBINE
GAS TURBINE W MP Steam
W
LP Steam
Q+W
HEAT PUMP
FURNACE W
PROCESS
Air Preheat
Refrigeration
Fuel W
Q+W
COOLING TOWER
Composite curve method only tells us the amount of utility required to satisfy the process
requirement. But it does not tell us the mix utilities that can be used
100
80
Minimum temperature difference = 10 C
60
40
30
H
1080 4640 720
And so does the problem table algorithm
960 QH
Stream Population DTint S CpC - S CpH DHint Surplus/Deficit
175 C
175 C
120
120 QC
To enable designer to determine the various utility mix that can be used, Grand Composite
Curve is useful. It is also a plot using T-H diagram.
Cp Q
180 C 80 C
HOT 1 20 2000
130 C 40 C
HOT 2 40 3600
120 C 30 C 36 3240
COLD 1
100 C 60 C
COLD 2 80 3200
From the problem table algorithm, the heat cascade was derived
0 960 QH
175 C 175 C
DH = - 1000 DH = - 1000
Adjust the
125 C 125 C
1000 heat 1960
cascade
DH = - 480 DH = - 480
105 C 105 C
1480 2440
DH = 1680 DH = 1680
75 C 75 C
-200 760
65 C
DH = 760 Highest ve 65 C
DH = 760
-960 value for heat 0
accumulated
35 C DH = -120 35 C DH = -120
-840 120
120 QC
The adjusted heat cascade is used to develop the Grand Composite Curve
T Grand Composite Curve
960 QH
960
175 C 175 C
DH = - 1000
125 C 125 C
1960
1960
DH = - 480
2440
105 C 105 C
2440
DH = 1680
75 C 75 C 760
760
65 C
DH = 760 65 C
0
35 C DH = -120 35 C
120
120
120 QC H
How do we use them ?
T We dont
Grand Composite Curve
necessarily
960 have to
175 C
supply the
heating
Lowest 1960
utility at this
125 C
temperature Heat Recovery/ temperature
QH = 960
where hot Process to Process 2440
utility could be 105 C Heat Transfer
supplied and
still satisfy the
heating 75 C
requirement 760
65 C
35 C
120
H
With the presence of multiple utilities, the selection for utilities will look more complex.
Furnace Heating
Hot Utility Furnace Heating
POCKETS OF
HEAT RECOVERY
MP Steam Heating
MP Steam level
PINCH
POCKETS OF
LP Steam level HEAT RECOVERY
1. Grand Composite curve provides the better insight for deciding multi level
utilities.
2. Satisfying hot utility requirement through steam, flue gas or hot oil
heating have different repercussion on the grand composite curve.
Similarly for cooling requirement where steam raising has different
repercussion on the grand composite curve compares to cooling water.
100oC
Heat exchanger
Heat exchanger in the GRID DIAGRAM
unit in a conventional
form CW 200oC 140oC 100oC
C
200oC 140oC
Q
160oC 80oC
HOT1 C
cooler
HOT2
COLD1
heater
H COLD2
Heat exchanger
Conventional rules:
hot streams run left to right
cold streams run right to left
hot streams on top, cold streams on bottom
hot utility heater, cold utility cooler
heat exchanger dumbell
Pinch divides the GRID DIAGRAM into 2 parts
120oC
HOT1 C
cooler
120oC
HOT2
100oC
COLD1
heater 100oC
H COLD2
Above Pinch Below
pinch pinch
With GRID DIAGRAM, pinch implications can be
assessed easily
120oC
C
120oC
100oC
100oC
H
No-No
1 2 Steam
1
E1 E3 E4
3 Cooling
water
E2 2 C
4
E5
Steam
Cooling E5
H 3
water
E4 E3 E1
4
E2
FCp
(MW/oC)
300oC 160oC 100oC
0.30 1
140oC
260oC
0.60 3
QH min = 28 MW QC min = 32 MW
STEP 1: Design should start from the pinch
Below Above
pinch pinch
DH
FCp
(MW/oC)
300oC 160oC 100oC
0.30 1
140oC
260oC
0.60 3
FCp
(MW/oC)
300oC 160oC 100oC
0.30 1
140oC
260oC
0.60 3
FCp
(MW/oC)
300oC 160oC 100oC
0.30 1
140oC
260oC
0.60 3
QH min = 28 MW QC min = 32 MW
Heat FCp
Load (MW/oC) 16 MW
(MW)
300oC 160oC 100oC
42 0.30 1
18 MW
18 200oC 160oC 40oC
0.45 2
140oC
72 260oC
0.60 3
QH min = 28 MW
STEP 3: Then fill in the rest
Heat FCp
Load (MW/oC)
(MW) 26 MW 16 MW
300oC 160oC 100oC
42 0.30 1
213.3oC 18 MW
18 200oC 160oC 40oC
0.45 2
o 28 MW 140oC
72 0.60 260 C 170oC
3
H
213.3oC
180oC 140oC 40oC
16 0.40 4
QH min = 28 MW
No violation of DT min !
Repeat STEP 2 for below the pinch
Heat
FCp Load
(MW/oC) (MW)
16 MW
300oC 160oC 100oC 18
1 0.30
18 MW 40 MW
200oC 160oC 40oC 0.45 54
2
71.1oC
140oC
260oC
3
QC min = 32 MW
Repeat STEP 3 for below the pinch
Heat
FCp Load
(MW/oC) (MW)
16 MW
18 MW
300oC 160oC 100oC 18
1 C 0.30
18 MW 40 MW
200oC 160oC 40oC 0.45 54
2 C
71.1oC
140oC
14 MW
260oC
3
QC min = 32 MW
Completed design
26 MW 16 MW 18 MW
300oC 160oC 100oC
1 C
213.3oC 18 MW
200oC 160oC 71.1oC 40oC
2 C
140oC
14 MW
260oC
28 MW
170oC
H 3
213.3oC
180oC 140oC 40oC
4
pinch
Divide at the pinch so that we have ABOVE and BELOW the pinch
Start at the pinch and move away
Above pinch: CPH CPC, Below pinch: CPH CPC
Use the tick-off heuristic to maximize loads
complete design by fill in the rest
CAB 3024_Sem Jul 07
Note:
You need to trade-off between operating cost and capital cost during the design of
heat exchanger network. Therefore, you are advice to check the literatures for most
cost-effective method of designing heat exchanger network.