CEB4313 – PROCESS INTEGRATION

HEAT INTEGRATION TARGETING

TECHNIQUES

Data Extraction
Composite Curves
Problem Table Algorithm

erniza.rozali@utp.edu.my
 The "Onion" Diagram
The complete hierarchy of process design
 Heat Integration
Design without heat integration

A stream that
needs cooling

A stream that Before heat

needs heating integration:
No. of heaters = 3
No. of coolers = 2
 Heat Integration
Design with heat integration

After heat
integration:
No. of heaters = 1
No. of coolers = 0

Heat integration results in capital and energy

cost savings!!
 Process Streams
Hot Cold

" Hot " streams require cooling " Cold " streams require heating

Temperature (oC)

200 oC Q 50 oC Q
Q = CP∙∆T

130 oC 0 oC

Enthalpy (kW)

CP = Product of mass flow and

specific heat capacity
 ΔTmin
ΔTmin = Minimum Permissible Temperature Difference

80o 70o
100o 60o 100o 60o
1 2

50o 40o

ΔTmin = 20 ºC

Which Exchanger Violates ΔTmin?

 T-H Representation of Heat
Exchangers
Plotting the change in temperature vs. enthalpy for the heat
exchanging streams provides a much clearer picture

T T

100 100
T = 20o
T = 30o
80 80

60 60 T = 20o
T = 10o

40 40
1 2

20 20
Q Q

H H
 Heat Exchanger Duty

100
CP = 0.3 𝑄 = 𝐶𝑃 ∙ ∆𝑇
80
𝑄 = 0.3 100 − 60
60

CP = 0.4 𝑄 = 0.4 70 − 40
40
𝑄 = 12 𝑀𝑊
20
Q

H
 Heat Integration
However, in industry…..

Many hot
streams

Many cold
streams

Designing heat exchanger networks (HEN)

requires a systematic approach!
 Pinch Analysis
• A systematic tool to design heat recovery networks for
maximum energy recovery

• Setting minimum energy targets based on 1st Law of

Thermodynamics, prior to design

Pinch Design Targets

• Minimum heating requirement (usually steam rate)
• Minimum cooling requirement (usually cooling water rate)
• Minimum number of units
• Minimum HEN area
 Pinch Analysis

2 Approaches:

• Composite curves (CC)

• Problem Table Algorithm (PTA)

DATA EXTRACTION
 Data Linearization

1 2 3 4

? ? ? ?

How should we linearize?

 Data Linearization
Use the Driving Forces
T Hot streams
hotter than hot
composite

Cold streams colder

than cold composite

H
Be conservative : linearize on the safe side
 Mixing

150º

100º

80º 50º 70º 30º

How do we extract the data?

 Mixing

150º T 100º
70º
100º 50º

80º 50º 70º 30º Q

MIXING acts as a heat transfer

unit
 Mixing
Therefore
150º

100º

80º 50º 70º 30º

30 º 150 º

30 º 80 º
 Mixing
Generally
150º

T= 30º 30º

80º

Mix isothermally so that no heat transfer takes

place during the mixing
 Utilities
Do NOT extract utilities (it is to be designed!)

Steam Cooling water

Do not extract existing utilities design.

Add them later using the grand composite curve.
 Soft Constraints

Option 1 Option 2

100º 80º Storage 100º 30º Storage

tank tank
80º 30º

The data is “soft”. What temperature to choose?

Check if hot/cold utilities can be reduced via composite curve
Data extraction – Summary

• Linearize on the safe side.

• Mix at the same temperature.

• Do not extract utilities.

• For soft data, apply +/- principle to reduce

targets.
 Data extraction
COND
20O C 170O C

∆H = 100 kW
∆H = 230 kW R2
60O C
C1

R1
REB COND
135O C
150O C 20O C
140O C
∆H = 330 kW 170O C
∆H = 150 kW

102.5O C
30O C
R2
60O C
90O C
C1
∆H = 90 kW
∆H = 90 kW ∆H = 230 kW
80O C
R1
REB
135O C
150O C

140O C

∆H = 180 kW ∆H = 240 kW

30O C
80O C
 Data extraction
Extracted Data

Supply Target
Heat Capacity
Temperature Temperature Load
Stream Type Flowrate
(°C) (°C) (kW)
(kW/oC)

1 Cold 20 135 230 2

2 Cold 80 140 240 4
3 Hot 170 60 330 3
4 Hot 150 30 180 1.5
COMPOSITE CURVES
 Composite Curves
Temperature – Enthalpy Diagram (T – ∆H Diagram)

Given the stream Stream Stream Tsupply Ttarget CP ∆H

number type (˚C) (˚C) (MW/K) (MW)
data :
1 Cold 40 130 2.0 180

T vs H Plot
T(°C)
Ttarget 130 smaller CP ∆H is a relative quantity.
Thus, the T-∆H line
can be shifted horizontally
T
bigger
H CP 1/CP is the slope of the
Tsupply 40 T-∆H line:
H (MW) ∆H = CP∆T ==> ∆T/∆H = 1/CP
 Composite Curves
The stream data

Supply Target
Heat Capacity
Temperature Temperature Load
Stream Type Flowrate
(°C) (°C) (kW)
(kW/oC)

1 Cold 20 135 230 2

2 Cold 80 140 240 4
3 Hot 170 60 330 3
4 Hot 150 30 180 1.5

∆Tmin = 20˚C
 Composite Curves
The cold composite curve

T (ºC) Individual T (ºC) Composite

140 CPC1
+ CPC2 CPC2
135
C2

80 Composite
C1 CPC1
(resultant)
Cold Stream

20

H (kW) H (kW)
230 240 120 330 20

C1+C2 = 470
 Composite Curves
The hot composite curve

Individual Composite
T (ºC) T (ºC)
170
CPH3 CPH3
150 H3 + CPH4

H4
60
CPH4
30

H (kW) 45 405 60 H (kW)

330 180

H3 + H4= 510
 Composite Curves
Hot and cold composites on the same T – ∆H diagram

T (ºC)
180

160

140

120 Hot composite Cold composite

curve curve
100

80

60

40

20

0 H (kW)
0 100 200 300 400 500 600 700 800
 Composite Curves
Composites together for ∆Tmin = 20˚C

T (ºC)
180 QH,min

160
140 Hot composite Cold composite
120 curve curve
100
∆Tmin Smallest ∆T (driving force).
80 - The most constrained part
60 of the process (in terms of
heat transfer) is at the Pinch
40
Process-to-process heat
QC,min
20 transfer
0
0 100 200 300 400 500 600 700
H (kW)
QH= External Heating Duty
QC= External Cooling Duty
 Composite Curves
Energy Targets
T (ºC)
180 QH,min = 65 kW

160
140
120
100 Tpinch = 90˚C
∆Tmin Tpinch = 100 °C for hot streams
80
Tpinch = 80 °C for cold streams
60
40
20
QC,min = 105 kW
0
0 100 200 300 400 500 600 700
H (kW)
QH= External Heating Duty
QC= External Cooling Duty
 Composite Curves
Effect of ∆Tmin
QH >QH,min
T (ºC)
QH,min

Move
horizontally

Pinch T > Tmin

Tmin

Less Process-to-Process
QC,min heat transfer

H (kW)
QC >QC,min
 Composite Curves
Effect of ∆Tmin

ΔTmin = 10 oC ΔTmin = 20 oC

ΔTmin = 30 oC ΔTmin = 40 oC
 Composite Curves
Typical ∆Tmin for various types of processes
 Composite Curves
Working Session 1

• Set up Stream Data Table

COND • Construct Composite Curves
60° • Read- Energy Targets for
Tmin = 10°C
80° 180°
C C
1 CP=20
R2
120°

REB H R1
130°
CP=80 100°
120°

C H
CP=40 CP=36

40°
30°
 Composite Curves
Working Session 1

Stream data table

Heat
Supply Target
Stream No Capacity
Temperature Temperature
and Type Flowrate
(°C) (°C)
(kW/°C)
1 Hot 180 80 20
2 Hot 130 40 40
3 Cold 60 100 80
4 Cold 30 120 36
 Composite Curves
Working Session 1

Composite hot stream

T ( C)
200

Hot 1
150 Hot 2

100

50

0 ΔH (kW)
0 2000 4000 6000
 Composite Curves
Working Session 1
Composite hot stream
T ( C)
200

150

100

50

0 ΔH (kW)
0 2000 4000 6000
 Composite Curves
Working Session 1

Composite cold stream

T (°C)
150

100
Cold 1

50
Cold 2

0 ΔH (kW)
0 2000 4000 6000 8000
 Composite Curves
Working Session 1

Composite cold stream

T (°C)

150

100

50

0 ΔH (kW)
0 2000 4000 6000 8000
 Composite Curves
Working Session 1
Composite curves
T(°C)220

200

160

120

80

40

0
H (kW)
1000 2000 3000 4000 5000 6000 7000
Composite Curves
Working Session 1

The Results

QHmin = 960 kW

QCmin = 120 kW

= 65 °C
TPinch (Interval)

TPinch (Hot) = 70 °C

TPinch (Cold) = 60 °C
PROBLEM TABLE ALGORITHM
Problem Table Algorithm

The Composite Curves

are complicated to build

An Alternative:
"Problem Table Algorithm"
 Problem Table Algorithm
The stream data

Supply Target
Heat Capacity
Temperature Temperature Load
Stream Type Flowrate
(°C) (°C) (kW)
(kW/oC)

1 Cold 20 135 230 2

2 Cold 80 140 240 4
3 Hot 170 60 330 3
4 Hot 150 30 180 1.5

∆Tmin = 20˚C
 Problem Table Algorithm
Shifted temperatures
T
Actual Hot - ∆Tmin/2
Shifted Cold + ∆Tmin/2

ΔTmin = 20 °C

Stream Type TS (°C) TT (°C) TS* (°C) TT* (°C)

1 Cold 20 135
2 Cold 80 140
3 Hot 170 60
4 Hot 150 30
 Problem Table Algorithm
Shifted temperatures
T
Actual Hot - ∆Tmin/2
Shifted Cold + ∆Tmin/2

ΔTmin = 20 °C

Stream Type TS (°C) TT (°C) TS* (°C) TT* (°C)

1 Cold 20 135 30 145
2 Cold 80 140 90 150
3 Hot 170 60 160 50
4 Hot 150 30 140 20
Problem Table Algorithm
Shifted temperature intervals
Interval Stream
Temperature Population
°C
160 3

150

145

CP = 4

CP = 3
140 4

90
CP = 2

CP = 1.5
50

30 1

20
 Problem Table Algorithm
Temperature interval heat balance
Interval Stream ∑CPH Surplus/
T(i+1)-Ti ∆Hinterval
Temperature Population -∑CPC Deficit
°C °C kW/K kW
160 3

10 3.0 30.0 Surplus

150
5 -1.0 -5.0 Deficit
145
CP = 4

5 -3.0 -15.0 Deficit

CP = 3

140 4
50 -1.5 -75.0 Deficit
90
CP = 2

40 2.5 100.0 Surplus

CP = 1.5

50
20 -0.5 -10.0 Deficit
30 1

10 1.5 15.0 Surplus

20
Problem Table Algorithm
Heat cascade
0.0 65
Add the
largest
(-) heat flow
30 30
95
30
-5 -5
25 90
-15 -15
10 75
-75 -75
Negative
-65 heat 0
100 flow! 100
35 100
-10 -10
25 90
15 15
40 105

Infeasible heat cascade Feasible heat cascade

 Problem Table Algorithm
Targets identification
QH,min 65

30
95
Minimum external heating duty
-5 = 65 kW
90 Minimum external cooling duty
-15 = 105 kW
75 T*pinch = 90 °C
-75
Hence, for ΔTmin = 20 °C
0 Pinch (Tint=90ºC )
100
Tpinch = 100 °C for hot streams
100 Tpinch = 80 °C for cold streams
-10
90
15
105 QC,min
Feasible heat cascade
 Problem Table Algorithm
Procedure summary

• The problem table algorithm:

STEP 1: Adjust For ΔTmin
STEP 2: Set up temperature intervals
STEP 3: Calculate interval heat balances
STEP 4: Assuming ZERO hot utility, cascade the balances from
higher to lower temperature intervals
STEP 5: Ensure positive Heat Flows by increasing the hot utility
as needed
STEP 6: Find QH,min, QC,min and Tpinch
 Problem Table Algorithm
Working Session 2

• Set up Stream Data Table

COND • Construct PTA
60° • Read- Energy Targets for
Tmin = 10°C
80° 180°
C C
1 CP=20
R2
120°

REB H R1
130°
CP=80 100°
120°

C H
CP=36
CP=40

40°
30°
 Composite Curves
Working Session 2

Stream data table

Heat
Supply Target
Stream No Capacity
Temperature Temperature
and Type Flowrate
(°C) (°C)
(kW/°C)
1 Hot 180 80 20
2 Hot 130 40 40
3 Cold 60 100 80
4 Cold 30 120 36
Problem Table Algorithm
Working Session 2

ΔTmin = 10 °C
TS TT T S* TT*
Stream
(°C) (°C) (°C) (°C)

1 180 80 175 75

2 130 40 125 35

3 60 100 65 105

4 30 120 35 125
 Problem Table Algorithm
Working Session 2

Shifted
Surplus/
Interval Stream Population ΔTinterval ΣCPH - ΔHinterval
Deficit
Temperature ΣCPC

1
175
50 20 1,000 Surplus
2
125
CP = 20

Surplus
20 24 480
105
30 -56 -1,680 Deficit
CP = 40

CP = 80

CP = 36

75
Deficit
10 -76 -760
65
3 Surplus
30 4 120
35
4
 Problem Table Algorithm
Working Session 2

T1*= 175° 0 +960

1,000 1,000

T2*= 125° +1,000 +1,960

480 480

T3*= 105° +1,480 +2,440

-1680 -1680

T4*= 75° -200 760

-760 -760

T5*= 65° -960 0

120 120

T6*= 35° -840 +120

Problem Table Algorithm
Working Session 2

The Results

QHmin = 960 kW

QCmin = 120 kW

= 65 °C
TPinch (Interval)

TPinch (Hot) = 70 °C

TPinch (Cold) = 60 °C