Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the...
Transcript of Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the...
![Page 1: Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the most methods used to design (HEN) and integrate heat since it introduced by Linnhoff](https://reader033.fdocuments.in/reader033/viewer/2022060503/5f1d08ea4d2db150777afd2a/html5/thumbnails/1.jpg)
Step by Step for Designing an Optimum Heat ExchangerNetworkEman M.Gabr
[email protected] Petroleum Research Institute
Abstract
Features of energy crisis became more complicated due to shortage of non- renewablesources of energy. While energy requirements increase parallel to technologyprogress. Energy researchers always apply energy targeting methodology to reduceutilities consumption. Designing a Heat Exchangers Network [HEN] by application ofpinch analysis is an effective technique for energy integration. I can say that this workis specific and simple course for designing a HEN through case study application.Where 8 alternatives Grass roots HEN designs with 66% of utilities saving areconcluded. Minimization of units and cost, process control and operability areimportant factors for choosing the suitable HEN design. Revamping of the existingprocess to maximize energy recovery with least alterations and cost took place; wherenet annual saving reached to 1,400,000 $.
Graphical AbstractWhat is the idea of Heat Exchanger Network??
Figure (1) the Idea of HENThrough two streams from any process
Transferring Heat Load from Source (hot stream H) to Sink (cold stream C)Replacement both Cooler and Heater by a Heat Exchanger
*Corresponding author: Eman Gabr / Assistant Professor (Head Manager of Reactor Engineering andProcesses Laboratory) Egyptian petroleum Research Institute. E-mail: [email protected]
H1 0 0 ?C 4 0 ?C C P =3 kw/?C
2 0 ?CC6 0 ?C CP =4.5 kw/?C
CoolerQ C =180 kw
H eat erQH =180 kw Heat
E xchangerQ =180 kw
H1 0 0 ?C 4 0 ?C
2 0 ?CC6 0 ?C
B efo re En ergy In te g ration A fte r E n erg y In te g rat io n
International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-2018ISSN 2229-5518 827
IJSER © 2018http://www.ijser.org
IJSER
![Page 2: Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the most methods used to design (HEN) and integrate heat since it introduced by Linnhoff](https://reader033.fdocuments.in/reader033/viewer/2022060503/5f1d08ea4d2db150777afd2a/html5/thumbnails/2.jpg)
Index Terms: Heat recovery, Energy saving, Pinch Analysis, Minimum utilities
Heat Exchanger Network HEN, Cost estimation, Optimum HEN.
1-Introduction
As population increase and technologydevelop; demand for energy increase whilein the same time we suffer from shortageof non-renewable sources, all these factorscomplete the energy crisis. Heat exchangernetwork (HEN) is an important techniquefor maximizing heat recovery in theindustrial chemical process and reducingexternal heating and cooling utilities.Extensive research has been done toimprove HENs design and synthesis overthe past 40 years [1].Pinch Analysis (PA); one of the mostmethods used to design (HEN) andintegrate heat since it introduced byLinnhoff and Flower [2] & Linnhoff andHinmarsh [3]. [Ahmad &Linnhoff andAhmad] [4,5] introduced the“Supertargeting” procedure for thedesign of near-optimal heat exchangernetwork which systematicallyconsiders the energy capital trade off.This method involves searching for theoptimum approach temperature thatyields the lowest total annual cost for aHEN designing.The effect of ∆Tmin contribution oncost was modified by Sun et al [6]where economical balance and analysisbetween the capital and operating costsfor a given ∆Tmin took place. Theeffect of heat – exchangers'specifications as material ofconstruction, equipment type and rateof pressure on the HEN cost hasmodified by [Hall, Ahmad and Smith][7].A methodology for determinationoptimum loads of multiple utilities totrade- off the capital and energy cost of
HEN was proposed by Shenoy et al.[8].Akbarnia, Amidpour, and Shadaram[9] added piping costs to the heatexchanger capital cost which improvesthe accuracy of capital cost 'estimation
and detects the optimum point fordesigning.Kravanja and Glavič [10] proposed asimultaneous optimization for HENcost targeting method based on processflow sheets using rigorous models anddetailed cost for HEN functions. Thenonlinear programming NLP model isa combination ofpinch technology and mathematicalprogramming and can be used to HENsynthesis with a large number ofstreams.Mixed-integer-linear programming(MILP) transportation method; wasformulated by Shethna, Jezowski, andCastillo [11] to optimize heatexchanging area, number of units andutilities load in order to achieveoptimum cost target for HEN.Reza, Reza, and Hassan [12]developed a mathematical modelwhich affected by specifications shelland tube heat exchanger (materials ofconstruction and heat transfercoefficients) in annual costoptimization of HEN.The MILP-MINLP Methodology byYee and Grossmann [13] was the basemodel for MO_MINLP simultaneousflexibility and operability technique fordesigning a flexible HEN. Where thisHEN; can maximize energy recovery
International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-2018ISSN 2229-5518 828
IJSER © 2018http://www.ijser.org
IJSER
![Page 3: Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the most methods used to design (HEN) and integrate heat since it introduced by Linnhoff](https://reader033.fdocuments.in/reader033/viewer/2022060503/5f1d08ea4d2db150777afd2a/html5/thumbnails/3.jpg)
although, there is deviation of thestreams 'conditions [14, 15, and 16].
2- Pinch Analysis Technique
We can consider the first “red” bookby Linnhoff et al. [17]; is the first stepfor prevalence of heat integration topicin research sector. This User Guide; isstill the massively cited in the literatureand is considered as the beginningoverview for energy integration.Where application of Pinch AnalysisTechnique (PAT); provides searcherswith catalogue for solving the problemof process integration. The techniqueproved integration successfullythrough heat exchanger networksynthesis, heat recovery targeting, andselecting multiple utilities [18].In (PAT) utilities integration andenergy recovery realized by
transforming the process streams intothe Composite Curves (CCs) [19].From (CCs), we can estimate theminimum external requirements of hotand cold utilities which are the non-overlapping segments of the cold andhot composite curvesMaximum heat recovery represents in(CCs) by the overlap region betweenhot and cold composites curves. CCsplay an important role in processdesign; for designing a Heat ExchangerNetwork (HEN) directly. The GrandComposite Curved (GCC) and theProblem Table Algorithm (PTA) arefurther development for heatintegration techniques. Whereminimum utilities and so on minimumemissions can be concluded [20].
2-1 Principles of Pinch Analysis
Pinch Technology provides asystematic methodology for energy
saving in processes and total sites. Themethodology is based onthermodynamic principles, the basisequations are:
T
H
T ∆
H ∆
Slope = 1/CP
CP=m Cp∆H = m Cp ∆T= CP ∆TCP = ∆H / ∆T
Where:m: mass flow rateCp: specific heat (physical property)CP: Heat Capacity flow rate∆H: Enthalpy Change∆T: Temperature Change
Figure (2) Presentation of hot stream on T-H diagram
2-2 Steps of Pinch Analysis Technique
1) Identification of hot, cold, utilitystreams in the process.
2) Extraction of thermal data forprocess streams and utilities.
3) Selection of Initial ∆Tmin value.
4) Estimation of minimum hot andcold utilities and defining ofpinch point by:
· Construction ofComposite Curves
International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-2018ISSN 2229-5518 829
IJSER © 2018http://www.ijser.org
IJSER
![Page 4: Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the most methods used to design (HEN) and integrate heat since it introduced by Linnhoff](https://reader033.fdocuments.in/reader033/viewer/2022060503/5f1d08ea4d2db150777afd2a/html5/thumbnails/4.jpg)
· Problem Table Algorithm5) Design of Heat ExchangerNetwork [HEN].6) Estimation of minimum energycost target.
7) Estimation of the capital costtarget.8) Identification of the optimum∆Tmin value.9) Design of the optimum HeatExchanger Network [HEN].
2-3 Estimation of minimum utilities
Maximum energy recovery for anyprocess leads to minimization of therequired external heating and coolingloads. Estimation of minimum hot andcold utilities through pinch analysis bytwo techniques (composite curve&problem table) is done as a beginningstep for HEN designing.
2-3-1 construction of CompositeCurve
Transferring of all hot streams whichpresented in T-H diagram into onecurve depending on Summation thestreams loads of the same interval; this
curve named as hot composite curve.By repeating this step with coldstreams; we get also cold compositecurve. The overlap region is the energyrecovery limits while the non overlapare the required heating and cooling.We can move composite curveshorizontally to change temperaturedifference which affects on utilities'loads and heat transfer area. Whiledetecting ∆Tmin value is realizingmaximum energy recovery andminimum utilities [21].See Figures (3 &4)
Figure (3) Construction of Composite Curves
International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-2018ISSN 2229-5518 830
IJSER © 2018http://www.ijser.org
IJSER
![Page 5: Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the most methods used to design (HEN) and integrate heat since it introduced by Linnhoff](https://reader033.fdocuments.in/reader033/viewer/2022060503/5f1d08ea4d2db150777afd2a/html5/thumbnails/5.jpg)
Figure (4) Definition of Pinch Point & control of ∆Tmin by sliding cold composite curve
2-3-2 Problem Table
It is an analytical method forestimation of minimum utilities and itsadvantage no need for especial utensilas graph paper and scissor.Steps of problem table method:• Divide the process into intervals• Limits of intervals are shifted
temperatures (hot streamstemperatures – 1/2 ∆Tmin) & (coldstreams temperatures + 1/2 ∆Tmin )
• Schematic representation of thestreams with a vertical temperaturescale took place through intervalboundaries (shifted temperaturesSi).See Figure (5)
• Enthalpy balances of every intervali, limited by shifted temperatures(Si & Si+1) can easily be calculatedas:
ΔHi = (Si–Si+1) (∑CPHot – ∑CPCold)i
• The positive magnitude ofenthalpy balance equation
named interval case as"surplus" while the negativenamed as "deficit" to produce afeasible network design basedon the assumption that all"surplus" intervals rejected heatto cold utility, and all "deficit"intervals took heat from hotutility.
• Beginning of external heatingof zero and accumulating ofintervals loads ascending todefine the highest deficit valuewhich represent minimum hotutility (QH).
• Cascading the process intervalwith (QH) with accumulating ofintervals loads will finalconclude minimum cold utility(QC) which is the load of lastinterval [22]
Pinch
Pinch point defined as the temperature correspondingto the shortest distance between hot and coldcomposite curves
Heat Recovery
International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-2018ISSN 2229-5518 831
IJSER © 2018http://www.ijser.org
IJSER
![Page 6: Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the most methods used to design (HEN) and integrate heat since it introduced by Linnhoff](https://reader033.fdocuments.in/reader033/viewer/2022060503/5f1d08ea4d2db150777afd2a/html5/thumbnails/6.jpg)
Figure (5) Vertical Representation of Streams on Shifted Temperatures Intervals
3- Design of Heat Exchanger Network
After classification the process intostreams with its thermal and physicalproperties, estimation of minimumutilities and defining pinch point.Now we can begin the more interestingpart which is HEN designing. Thepinch separates the process into twosubnetwork designs; above and belowpinch.To achieve maximum energy
recovery we must apply these nextsteps:
1. Do not transfer heat across thepinch point.
2. Do not use hot utility below thepinch point.
3. Do not use cold utility above thepinch point.
4. Begin with pinch match and moveaway.
5. Pinch matches obey this rule:· CPhot<=CPcold (above pinch)· CPhot>=CPcold (below pinch)
Algorithm of HEN designing is shown in Fig. 6
Figure (6) Sequences for designing HEN above pinch (a) and below pinch (b)
Si = (Thin – 1/2 ∆Tmin) Thin
Si+1= (TCout + 1/2 ∆Tmin) TCout
Si+2= (Thout - 1/2 ∆Tmin) Thout
Si+3 = (TCin + 1/2 ∆Tmin) TCin
hi
Cj
International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-2018ISSN 2229-5518 832
IJSER © 2018http://www.ijser.org
IJSER
![Page 7: Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the most methods used to design (HEN) and integrate heat since it introduced by Linnhoff](https://reader033.fdocuments.in/reader033/viewer/2022060503/5f1d08ea4d2db150777afd2a/html5/thumbnails/7.jpg)
4- Economic Analysis of HEN Design
By applying pinch analysis technique,we can get many alternative designsfor the same process. Economicbalancing by cost estimation of every
design helps us to reach to theoptimum one.Cost Estimation Equations are:
Ann.Overall Cost of HEN = Ann.Capital Cost + Ann.Operating Cost
Ann.Capital Cost = Capital cost of Units / life time
Capital cost of unit = ƒ [A] …… (A Ξ heat transfer area)
A = Q / U * ΔTlm
Where:Q = heat load of the unit1 / U = 1 / hi + 1 / hj …….. (hΞ heat transfer coefficient)
ΔTlm = (T1 – t2) – (T2 – t1) /ln (T1 – t2) / (T2 – t1)Life time = 6 yearsCost of piping = 8% Installed cost of Equipment
i
j
T1
t2
T2t1
v Capital cost:
Effect of ∆Tmin on heat transfer area and capital cost is shown as next diagram:
· Capital cost affected by number of units and minimum number of units for anyHEN can be estimated by next equation:
Nmin = Nh +Nc +Nu -1Where:
Nmin = Minimum Number of UnitsNh = Number of hot streamsNc = Number of cold streamsNu = Number of utilities
v Operating Cost
NuTotal Operating Cost = ∑ Qu * Cu
u=1
Where: Qu = Duty of utility U, kW
International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-2018ISSN 2229-5518 833
IJSER © 2018http://www.ijser.org
IJSER
![Page 8: Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the most methods used to design (HEN) and integrate heat since it introduced by Linnhoff](https://reader033.fdocuments.in/reader033/viewer/2022060503/5f1d08ea4d2db150777afd2a/html5/thumbnails/8.jpg)
Cu = Unit cost of utility U, $ / KW.yr
Nu = Total Number of utilities
5- Application of Pinch Analysis Technique on a case study
I applied Pinch technique on a casestudy with a plant flowsheet shown inFigure (7). Where:
• The feed is heated to the reactiontemperature.
• The reactor effluent is furtherheated, and the products areseparated in a distillation column.
• The reboiler and condenser useexternal utilities for controlpurposes.
• The overhead and bottomsproducts are cooled and sent forfurther processing.
Classification the process into streamswith its thermal and physical propertiesis shown in table (1)As a beginning for HEN design Irepresent the streams in the form ofgrid diagram as shown in Figure (8)where the actual consumption ofexternal utilities is:Heating load = 14000 KwCooling load = 13800 KwCost of hot utility = 140.2 $/ KW.yrCost of cold utility = 7.1 $/ KW.yr
H
H
C
C
H
C
Reactor FeedC1
Reactor EffluentC2
20 ᵒC 160 ᵒC
Reac
tor
120 ᵒC
OverheadProduct
H1
BottomProduct
H2
180ᵒC
260 ᵒC
20ᵒC
280ᵒC60ᵒC
Col
umn
Figure (7) A Typical Plant Flowsheet of the case study
International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-2018ISSN 2229-5518 834
IJSER © 2018http://www.ijser.org
IJSER
![Page 9: Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the most methods used to design (HEN) and integrate heat since it introduced by Linnhoff](https://reader033.fdocuments.in/reader033/viewer/2022060503/5f1d08ea4d2db150777afd2a/html5/thumbnails/9.jpg)
Table (1): Streams data of the case study
COver headproductH1
H2Bottomproduct C
180 C 20 C
280 C 60 C
C1ReactorFeed
20 CH
H
160 C
C2Reactoreffluent
120 C260 C
CP KW / C
45
30
40
60
Hot Pinch(150 C)
Cold Pinch(120 C)
Q =7200 KW
Q=6600 KW
Q=5600 KW
Q=8400 KW
Actual Cooling Load = 13800 KWActual Heating Load = 14000 KW
Figure (8) Grid Diagram of the Flowsheet
5-1 Estimation of Minimum Hot and Cold Utilities
· With ∆Tmin of 30ᵒC; minimum hot and cold utilities of the process estimated bygraphical composite curve as shown in Figure (9).
Where [QHmin = 4750 KW, QCmin = 4550 KW, Thp= 150 ᵒC and Tcp = 120ᵒC]
· The Analytical problem table method got the same results of minimum utilitiesand pinch point as shown in Figures (10, 11) and Table (2)
International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-2018ISSN 2229-5518 835
IJSER © 2018http://www.ijser.org
IJSER
![Page 10: Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the most methods used to design (HEN) and integrate heat since it introduced by Linnhoff](https://reader033.fdocuments.in/reader033/viewer/2022060503/5f1d08ea4d2db150777afd2a/html5/thumbnails/10.jpg)
Qhmin
4750 KW
Qcmin
4550 KW
Pinchpoint
Tmin = 30 C
0 5000 10000 15000 20000Enthalpy KW
300
250
200
150
100
50
0
Tem
pera
ture
C
Thp=150 C
Tcp=120 C
Figure (9) Estimation of Minimum Utilities by Composite Curve
TB = Si =Th – ½ TminTB = Si = Tc + ½ Tmin
TB + ½ Tmin CTB
1
2
3
4
5
6
7
275
265
175
165
135
45
35
5
H1
290
280
190
180
150
60
50
20
H2
C1
C2
Ts=120 C
Ts=20 C
Ts=280 C
Ts=180 C
Tt=20 C
Tt=60 C
Tt=260 C
Tt=160 C
CP=60
CP=40
CP=30
CP=45
C
Figure (10) Representation of Streams on Boundary Intervals
International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-2018ISSN 2229-5518 836
IJSER © 2018http://www.ijser.org
IJSER
![Page 11: Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the most methods used to design (HEN) and integrate heat since it introduced by Linnhoff](https://reader033.fdocuments.in/reader033/viewer/2022060503/5f1d08ea4d2db150777afd2a/html5/thumbnails/11.jpg)
Table: (2) Definition and Calculation of Enthalpy Change for Every Interval
BoundaryPinch pointThp=150 CTcp= 120 C
ΔH=600KW
2700
700
750
-3150
-50
-1350
ΔH=600KW
2700
700
750
-3150
-50
-1350
275 C
265
175
165
135
45
35
5
O KW
-600
-3300
-4000
-1600
-1550
-200
QHmin = 4750 KW
4150
1450
750
0
3150
3200
QCmin = 4550 KW
Figure (11) Estimation of minimum Utilities by Problem Table Algorithm through heat CascadePrinciple
5-2 Designing of Subnetworks for the Case Study
By applying pinch technique sequencesfor HEN designing as mentionedbefore in text 3, four subnetworksalternatives are concluded .Two above
Pinch. See Figures (12-a) & (12-b) andthe other two subnetworks weredesigned below pinch point. SeeFigures (12-c) & (12-d).
Temperature TC
IntervalNO Ti - Ti+1 ∑CPcold - ∑CPhot ΔHi
Surplus orDeficit
275
265
175
165
135
45
35
5
1 10 60 600 Deficit
2 90 30 2700 Deficit
3 10 70 700 Deficit
4 30 25 75 Deficit
5 90 -35 -3150 Surplus
6
7
10
30
-5
-45
-50
-1350
Surplus
surplus
International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-2018ISSN 2229-5518 837
IJSER © 2018http://www.ijser.org
IJSER
![Page 12: Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the most methods used to design (HEN) and integrate heat since it introduced by Linnhoff](https://reader033.fdocuments.in/reader033/viewer/2022060503/5f1d08ea4d2db150777afd2a/html5/thumbnails/12.jpg)
5-3 Synthesis of HEN Designs by Subnetworks Combination
By combination between every two subnetworks (above –below); I got fouralternatives HEN designs for the case study, Figures (13-a, 14-a, 15-a, and 16-a). Allthe designs achieved minimizing of utilities but differed in matching and number ofunits. As a result of combination; loops appear due to match repeating between thesame streams as represented in Figures by purple dashed line. In this case;modification of design by breaking the loop is required by replacement the 2 H.E with1 to minimize the units 'number and so on reduce capital cost as shown in Figures (13–b, 14-b, 15-b and 16-b) .The summary of the economic analysis of the modifieddesigns is shown in table (3); where HEN of Fig.15-b has the least cost.
Figure (13- a) First alternative HEN design, combination between (12-a) and (12-d)
H1
H2
C2
Thp = 150 C
Tcp = 120 C
1350 KW
1600 KW2301 KW
180 C
280 C 203.3 C
160 C
142.5 C180.85 C
QHmin = 4750 KW
260 C
CP KW/ C
45
30
40
60
C1
Pinchmatch
CPhot ≤CPcold
1300 KW
C1
Thp = 150 C
Tcp = 120 C
4550 KW
2700 KW
121.11 C 20 C
60 C
20 C
CP KW/ C
45
30
40
PinchmatchCPhot ≥Cpcold
H1
H2
C2
Thp = 150 C
Tcp = 120 C
1350 KW
3901 KW
180 C
280 C
160 C
185. C
4500 KW
260 C
CPKW/ C
45
30
40
60
C1
Pinchmatch
CPhot ≤CPcold
153.75 C
250 KW
4000 KW
C1
Thp = 150 C
Tcp = 120 C
1850 KW
2700 KW
61.1 C 20 C
60 C
20 C
CP KW/ C
45
30
40
PinchmatchCPhot ≥Cpcold
1300 KW
H1
H2
1350 KW
1600 KW2301 KW
180 C
280 C 203.3 C
160 C
142.5 C180.85 C
QHmin = 4750 KWQCmin = 4550 KW
260 C
CP KW/ C
45
30
40
60
C1
Thp = 150 C
Tcp = 120 C
4550 KW
2700 KW
121.11 C 20 C
60 C
20 C
CP KW/ C
45
30
40
Qhmin=4750 KW
No of Units = 7
No of Units = 7
Qcmin= 4550 KW
Qcmin= 4550 KWQcmin= 4550
Figures (12-a) & (12-b) Subnetworks above pinch
Figures (12-c) & (12-d) Subnetworks below pinch
International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-2018ISSN 2229-5518 838
IJSER © 2018http://www.ijser.org
IJSER
![Page 13: Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the most methods used to design (HEN) and integrate heat since it introduced by Linnhoff](https://reader033.fdocuments.in/reader033/viewer/2022060503/5f1d08ea4d2db150777afd2a/html5/thumbnails/13.jpg)
Figure (13-b) First alternative HEN design after loop breaking
Figure (14-a) Second alternative HEN design, combination between (12-b) and (12-c)
Figure (14-b) Second alternative HEN design after loop breaking
1300 KW
H1
H2
1350 KW
2301 KW
180 C
280 C 203.3 C
160 C
142.5 C180.85 C
QHmin = 4750 KWQCmin = 4550 KW
260 C
CP KW/ C
45
30
40
60
C1
4550 KW
4300 KW
121.11 C 20 C
60 C
20 C
C2
4000 KW
H1
H2
C2
Thp = 150 C
Tcp = 120 C
1350 KW
3901 KW
180 C
280 C
160 C
185. C
4500 KW
260 C
CP KW/ C
45
30
40
60
153.75 C
250 KW
C1
1850 KW
2700 KW
61.1 C 20 C
60 C
20 C
5350 KW
H1
H2
C2120 C
3901 KW
180 C
280 C
160 C
185. C
4500 KW
260 C
CP KW/ C
45
30
40
60
153.75 C
250 KW
C1
1850 KW
2700 KW
61.1 C 20 C
60 C
20 C
No of Units = 7QHmin = 4500 + 250 = 4750 KWQcmin = 2700 +1850= 4550 KW
No of Units = 6
No of Units = 6QHmin = 4500 + 250 = 4750 KWQcmin = 2700 +1850= 4550 KW
International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-2018ISSN 2229-5518 839
IJSER © 2018http://www.ijser.org
IJSER
![Page 14: Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the most methods used to design (HEN) and integrate heat since it introduced by Linnhoff](https://reader033.fdocuments.in/reader033/viewer/2022060503/5f1d08ea4d2db150777afd2a/html5/thumbnails/14.jpg)
Figure (15-a) Third alternative HEN design, combination between (12-b) and (12-d)
Figure (15-b) Third alternative HEN design after loop breaking
Figure (16-a) Fourth alternative HEN design, combination between (12-a) and (12-c)
1300 KW
H1
H2
C2
1350 KW
3901 KW
180 C
280 C
160 C
185. C
4500 KW
260 C
CP KW/ C
45
30
40
60
153.75 C
250 KW
C1
Thp = 150 C
Tcp = 120 C
4550 KW
2700 KW
121.11 C 20 C
60 C
20 C
2650 KW
H1
H2
C2
3901 KW
180 C
280 C
160 C
185 C
4500 KW
260 C
CP KW/ C
45
30
40
60
153.75 C
250 KW
C1
4550 KW
2700 KW
121.11 C 20 C
60 C
20 C
4000 KW
H1
H2
1350 KW
1600 KW2301 KW
180 C
280 C 203.3 C
160 C
142.5 C180.85 C
QHmin = 4750 KWQCmin = 1850 + 2700= 4550 KWNo of Units = 7
260 C
CP KW/ C
45
30
40
60
C1
1850 KW
2700 KW
61.1 C 20 C
60 C
20 C
4750 KW
No of Units = 7QHmin = 4500 + 250 = 4750 KWQcmin = 4550 KW
No of Units = 6 QHmin = 4500 + 250 = 4750 KWQcmin = 4550 KW
Thp = 150 ᵒC
Thp = 120 ᵒC
International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-2018ISSN 2229-5518 840
IJSER © 2018http://www.ijser.org
IJSER
![Page 15: Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the most methods used to design (HEN) and integrate heat since it introduced by Linnhoff](https://reader033.fdocuments.in/reader033/viewer/2022060503/5f1d08ea4d2db150777afd2a/html5/thumbnails/15.jpg)
Figure (16-b) Fourth alternative HEN design after loop breaking
Table (3) Economic Analysis of the HEN Designs
5-4 Revamping of the Case Study through Heat Recovery Technique
As a new design (grass-root) for the case study; all the last alternatives HEN designscan be used according to availability and operability conditions. While the revampingtechnique depends on choosing the least alterations HEN design compared to theexisting. That's guarantees minimizing added capital cost. So The HEN design ofFigure (14-b) is our pivot for existing process revamping. The modification is onlyadding two heat exchangers represented by yellow circles as shown in Figure (17).Maximum energy recovery realized where external heating reduced from 13800 to4750 KW and external cooling reduced from 14000 to 4550 KW. The summary ofeconomic analysis due to revamping is shown in Table (4); where the net saving isaround 1,400,000 $/y
20 o C 160 ᵒC
120 ᵒC
HH1
H2
C1
C2
4750 KW
3651 KW
5600 KW 1600 KW
2950 KW
55.6 o C 20 ᵒC
60 ᵒC158.3 o C
180.6 ᵒC
180 ᵒC
280 ᵒC
260 ᵒC
CP KW/ᵒC
45
30
40
60
Figure 13-b Figure 14-b Figure 15-b Figure 16-b
Capital Cost$/y
141665.7 134423.7 130550.9 168335.2
Capital Cost*C.I $/y
153000.0 145177.6 140995.0 181802.02
Cost of Hotutility $/y
665950 665950 665950 665950
Cost of Coldutility $/y
32305 32305 32305 32305
Operating Cost$/y
698255 698255 698255 698255
Overall Cost$/y
851255 843433 839220 880057
QHmin = 4750 KW, QCmin = 4550 KW, NO of Units = 5
International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-2018ISSN 2229-5518 841
IJSER © 2018http://www.ijser.org
IJSER
![Page 16: Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the most methods used to design (HEN) and integrate heat since it introduced by Linnhoff](https://reader033.fdocuments.in/reader033/viewer/2022060503/5f1d08ea4d2db150777afd2a/html5/thumbnails/16.jpg)
H
H
C
C
H
C
Reactor FeedC1
Reactor EffluentC2
20 C 160 C
Reac
tor
120 ºC
OverheadProduct H1
BottomProduct H2
180 C
260ºC20 C
150 ºC 60 ºCC
olum
n
H.E
5350 KW153.75 C
61.1 C
1850 KW
250 KW
185 ºCH.E
3901 KW4500 KW
2700 KW280 ºC
QHact.= 13800 KW, QHmin = 4750 KWQcact.= 14000 KW, Qcmin = 4550 KW
Figure (17) The flowsheet of the case study after revamping
Table (4) Economic Analysis for Revamping the Case study
International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-2018ISSN 2229-5518 842
IJSER © 2018http://www.ijser.org
IJSER
![Page 17: Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the most methods used to design (HEN) and integrate heat since it introduced by Linnhoff](https://reader033.fdocuments.in/reader033/viewer/2022060503/5f1d08ea4d2db150777afd2a/html5/thumbnails/17.jpg)
Conclusion
This study is a summary of pinch analysis to design Heat Exchanger Network HENstep by step. Designing of HEN is an effective technique for maximizing energyrecovery and so on minimizing external utilities. It's proved its validity throughapplication on a case study where percentage of utilities' saving reached to (65% &68%) for hot utility and cold utility respectively. The process revamping got excellentresults where maximization of saving realized by least alterations represented inadding two heat exchangers and the net annual saving reached to 1,382,893 $ which isgreat.
Recommendation
This technique is recommended for any chemical process where energy saving is aninternational target for all countries (rich or poor). We need to reduce energyconsumption to save money and protect environment.
Acknowledgment
The author acknowledges Egyptian Petroleum Research Institute for continuouslysupport.
Nomenclature
Qhmin: Minimum hot utility (kW)Qcmin: Minimum cold utility (kW)∆Tlm: Minimum temperature difference log meanThp: hot pinch point (ᵒC)Tcp: cold pinch point (ᵒC)TB: Boundary temperature (ᵒC)Ts: Supply temperature (ᵒC)Tt: Target temperatureA: heat exchanger area (m2)hi: heat transfer coefficient of hot stream (kW/m2 ᵒC)hj: heat transfer coefficient of cold stream (kW/m2 ᵒC)U: Overall heat transfer coefficient (kW/m2 ᵒC)Nmin = Minimum Number of UnitsNh = Number of hot streamsNc = Number of cold streamsNu = Number of utilitiesH: enthalpy (kW)CP: heat capacity flow rate (kW/ᵒC)T1: Inlet temperature of hot stream (ᵒC)T2: outlet temperature of hot stream (ᵒC)t1: inlet temperature of cold stream (ᵒC)t2: outlet temperature of cold stream (ᵒC)∆Tmin: minimum temperature difference approach
References:
1-Suraya Hanim Abu Bakar, Mohd. Kamaruddin Abd. Hamid, Sharifah Rafidah Wan Alwi,Zainuddin Abdul Manan. Selection of minimum temperature difference (∆Tmin) for heatexchanger network synthesis based on trade-off plot. Applied Energy , 2015.
International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-2018ISSN 2229-5518 843
IJSER © 2018http://www.ijser.org
IJSER
![Page 18: Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the most methods used to design (HEN) and integrate heat since it introduced by Linnhoff](https://reader033.fdocuments.in/reader033/viewer/2022060503/5f1d08ea4d2db150777afd2a/html5/thumbnails/18.jpg)
2- Linnhoff B, Flower JR. Synthesis of heat exchanger networks: I. Systematicgeneration of energy optimal networks. AIChE J 1978; 24:633–42.
3- Linnhoff, B.,Hindmarsh,E.,1983.The pinch design method for heat exchangernetworks.Chem.Eng.Sci.38,745–763.
4- Ahmad, S. (1985). Heat exchanger networks: Cost trade-offs in energy andcapital. PhD Thesis, UMIST, UK.
5- Linnhoff, B., & Ahmad, S. (1990). Cost optimum heat exchanger networks-1.Minimum energy and capital using simple models for capital cost. Computers &Chemical Engineering, 14, 729–750.
6- Sun KN, Wan Alwi SR, Manan ZA. Heat exchanger network cost optimization consideringmultiple utilities and different types of heat exchangers. Comput Chem. Eng 2013;49:194–204.
7- Hall, S. G., Ahmad, S., & Smith, R. (1990). Capital cost targets for heat exchangernetworks comprising mixed materials of construction, pressure ratings and exchangertypes. Computers & Chemical Engineering, 14(3), 319–335.
8- Shenoy, U. V., Sinha, A., & Bandyopadhyay, S. (1998). Multiple utilities targetingfor heat exchanger networks. Transactions of IChemE, 76(Part A), 259–272.
9- Akbarnia, M., Amidpour, M., & Shadaram, A. (2009). A new approach in pinchtechnology considering piping costs in total cost targeting for heat exchanger network.Chemical Engineering Research and Design, 87, 357–365.
10- Kravanja, Z., & Glavič, P. (1997). Cost targeting for HEN through simultaneousoptimization approach: A unified pinch technology and mathematical programmingdesign of large HEN. Computers & Chemical Engineering, 21(8), 353–833.
11- Shethna, H. K., Jezowski, J. M., & Castillo, F. J. L. (2000). A new methodologyfor simultaneous optimization of capital and operating cost targets in heat exchangernetwork design. Applied Thermal Engineering, 20(15–16), 1577–1587.
12- Reza, H., Reza, M., & Hassan, O. M. (2004). Cost effective heat exchangernetwork design with mixed materials of construction. Iranian Journal of Chemistryand Chemical Engineering, 23(2), 89–100.
13- Yee, T.F., Grossmann, I.E., Simultaneous optimization of models for heatintegration. II. Heat exchanger network synthesis. Computers and ChemicalEngineering 14 (10), (1990), 1165–1184.
14- Konukman, A., C¸ amurdan, M., Akman, U., Simultaneous flexibility targeting andsynthesis of minimum-utility heat-exchanger networks with superstructure-based MILPformulation. Chemical Engineering and Processing 41 (6), (2002), 501–518.
International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-2018ISSN 2229-5518 844
IJSER © 2018http://www.ijser.org
IJSER
![Page 19: Step by Step for Designing an Optimum Heat Exchanger Network · Pinch Analysis (PA); one of the most methods used to design (HEN) and integrate heat since it introduced by Linnhoff](https://reader033.fdocuments.in/reader033/viewer/2022060503/5f1d08ea4d2db150777afd2a/html5/thumbnails/19.jpg)
15- Verheyen, W., Zhang, N., Design of flexible heat exchanger network for multi-periodoperation. Chemical Engineering Science 61 (23), (2006), 7730–7753.
16- EL-Temtamy, S. A., Gabr, E. M., Design of optimum flexible heat exchangernetworks for multiperiod process. Egyptian Journal of Petroleum 21, (2012), 109–117
17- B. Linnhoff, D.W. Townsend, D. Boland, G.F. Hewitt, B.E.A. Thomas, A.R. Guy,R.H. Marsland, A User Guide to Process Integration for the Efficient Use of Energy.IChemE, Rugby, UK, 1982, last edition 1994.
18- Friedler F. ,Process integration, modeling and optimization for energy savingand pollution reduction. Applied Thermal Engineering 30 (2010) 2270- 2280.
19 - B. Linnhoff, E. Hindmarsh, The pinch design method for heat exchangernetworks. Chemical Engineering Science 38 (5) (1983) 745-763.
20- D.W. Townsend, B. Linnhoff, Heat and power networks in process design.Part II: design procedure for equipment selection and process matching.AIChE Journal 29 (5) (1983) 748-771.
21- B. Linnhoff, Introduction to Pinch Technology , Linnhoff March,www.linnhoffmarch.com,Copyright 1998
22- Ian C Kemp, Pinch Analysis and Process Integration-A User Guide on ProcessIntegration for the Efficient Use of Energy. First edition 1982, Second edition Copyright ©2007, Elsevier Ltd. All rights reserved
International Journal of Scientific & Engineering Research Volume 9, Issue 7, July-2018ISSN 2229-5518 845
IJSER © 2018http://www.ijser.org
IJSER