Prof Jean Mulopo

Part 2
Memo Tutorial- Heat Integration-

Table Algorithm & Area Targeting

& Cost Targeting
Problem 1: The stream data for a typical process plant is given in Table 1 for which ∆Tmin =
10⁰C. Calculate the hot and cold utility and pinch point for this process.

Table 1: Stream data for typical process plant

Stream Name Stream Type TS ( 0C) TT ( 0C) CP (kW/ 0C)

1 Cold(C1) 10 45 120

2 Hot(H1) 45 15 110

3 Cold(C2) 50 85 5

4 Hot(H2) 85 15 5

5 Cold(C3) 10 75 25

6 Cold(C4) 45 80 20

7 Hot(H3) 40 10 120

Prof Jean Mulopo1

Solution to Problem-1:

The first step to calculate hot and cold utilities is to find out the shifted temperatures for the hot
and cold streams as shown below:

TH(shifted) = TH(actual) - ∆Tmin/2 (1)

TC(shifted) = TC(actual) + ∆Tmin/2 (2)

Values of shifted temperatures of hot and cold streams are shown in Table 2.
 Table 2: Shifted temperature data for stream data of Table 1

Stream type Actual temperature ( 0C) Shifted temperature ( 0C)

Supply Target Supply Target

Temperature Temperature Temperature Temperature
H1 45 15 40 10
H2 85 15 80 10
H3 40 10 35 5
C1 10 45 15 50
C2 50 85 55 90
C3 10 75 15 80
C4 45 80 50 85

The shifted temperatures are arranged in decreasing order where the temperature, which appears
more than one, should be written only once. It gives temperature intervals as shown in column
no. 1 of Table 3.

Enthalpy balances can easily be calculated for each temperature interval using Eq. 3:

∆ ∑ ∑ ∆ ∗ ∑ ∑ (3)

This equation is valid for any temperature interval i. The computed heat balance in all the
temperature intervals are shown in the Table 3. The last column of this table indicates whether
the interval is in heat surplus or heat deficit.
 Table 3: Temperature interval and heat balance in each interval

Shifted Stream population TI - TI+1 ∑ ∆H(kW) surplus

temperature (⁰C) 5 ∑ or deficit
90
CP
20 5 5 25 Deficit
85
5 25 5 25 125 Deficit
80
25 45 1125 Deficit
55 120
C2 5 40 200 Deficit
50
110 C4 10 140 1400 Deficit
40
120 5 30 150 Deficit
35
20 -90 -1800 Surplus
15
C1 C3 5 -235 -1175 Surplus
10
H2 5 -120 -600 Surplus
5 H1
H3

After constructing the Problem table and defining intervals with surplus and deficit of heat, the
next step is to develop a heat cascade based on key feature of problem table that any heat
available in interval i is hot enough to supply its duty in interval i+1. The cascading is shown in
column no. 3 of Table 4. Further, the column shows negative values of heat in a interval, which
is infeasible. To make the problem feasible most negative value of heat, which is 3025 kW
(column 3 in Table 4), is cascaded from top and considered as hot utility. The cascading is
shown in last column of Table 4.
 Table 4: Problem table cascade 3025kW

Shifted ∆H (kW) Heat cascade Heat cascade

temperature at stage 1, at stage 2,
(⁰C) ∆H (kW) ∆H (kW)
90 0 3025 Hot utility
25
85 -25 3000 3025-25 = 3000
125
80 -150 2875 3000-125 = 2875
1125
55 -1275 1750 2857-1125=1750
200
50 -1475 1550 Add to the TOP
1400 temp. level with
40 -2875 150 sign change ( i.e.
150 3025 kW) and then
Pinch
35 -3025 0 cascade down
point
-1800 satisfying the heat
15 -1225 1800 demand and supply
-1175
10 -50 2975
-600
5 550 3575 Cold utility

From the problem table cascade shown in Table 4 following information are extracted:

Amount of minimum hot utility required: 3025 kW

Amount of minimum cold utility required: 3575 kW

Pinch point: 35 0C

Hot pinch : 40 0C

Cold pinch : 30 0C
Problem 2: For a process the stream data together with utility data and heat transfer
coefficients are shown in Table 2, where ∆Tmin is selected as 10 °C. Steam from 250°C to 249°C
is to be used as hot utility, however, cold water at 25 °C and returning to the cooling tower at
35 °C is to be used as cold utility. Target the heat exchange area for this process.

Table 2: The stream and utility data for the process

Stream Supply Target H Heating Film heat

temperature temperature (MW) capacity flow transfer
Ts(C) TT(C) rate, CP coefficient, h
(MW.⁰C-1) (MW.m-2.⁰C-1)

Cold (C1) 25 185 32.0 0.25 0.0008

Hot (H1) 260 50 -31.5 0.16 0.0009

Cold (C2) 145 235 27.0 0.32 0.0009

Hot (H2) 190 70 -30.0 0.26 0.0010

Steam (HU) 250 249 0.0040

Cold water 25 35 0.0010

(CU)

Prof Jean Mulopo2

 Solution 2: To calculate area target for the given stream data in Table 2 the amount of hot
and cold utility is computed using Problem Table Algorithm (PTA) and results are found to
be:

Amount of hot utility: 12.9MW

Amount of cold utility: 8.90MW

Pinch point: 150⁰C

Hot pinch: 155⁰C

Cold pinch: 145⁰C

CP of hot and cold utility are computed as 12.9 MW/˚C and 0.89 MW/˚C, respectively.

300

Th7 Th8 Th9

Th6
250

200 Balanced hot composite curve Th5

Tc9
Temperature˚C

Th4

150 Tc6

Th3
Tc4
100 Th2

Th1

50 Balanced cold composite curve

Tc3
Tc1
0
0 10 20 30 40 50 60 70 80 90
Enthalpy MW

Graphical representation of balanced hot and cold composite curve

The total heat transfer area is 6520.636 m2.

Problem 3: Compute the cost targeted for stream data shown in Table 3, where two hot streams
exchange heat against a single cold stream assuming ∆Tmin as 10°C. The overall heat transfer
coefficient, U, is constant and is equal to 0.123 kW.m-2K-1 for all exchangers.

Table 3: Stream data for Problem 3

stream Supply Target Heat capacity

temperature, Ts temperature, Tt flow rate, CP
(˚C) (˚C) (kW.⁰C-1)
HOT (H1) 180 140 1.4
HOT (H2) 150 90 2.5
COLD (C1) 70 150 4

Given:

(a) The capital cost of the individual heat exchangers is according to following relationship:

Heat exchanger capital cost ($) = 30,000 + 400 (A) 0.9

Where, A is the heat transfer area of exchanger in m2.

(b) The utility costs are:

Steam cost = 120,000 ($.kW-1.y-1)

Cooling water cost = 10,000 ($.kW-1.y-1)

(c) Plant life and rate of interest are assumed as 5 years and 10%, respectively.
 Solution : To calculate the area target for the given stream data in Table 3, first the
amount of hot and cold utility and the pinch temperature should be known.

Stream Supply Target Shifted supply Shifted target

temperature temperature temperature temperatures
Ts(˚C) Tt(˚C) Ts(˚C) Tt(˚C)
HOT (H1) 180 140 175 135
HOT (H2) 150 90 145 85
COLD (C1) 70 150 75 155

From the problem table analysis it is clear that-

Hot utility : 114 kW

Cold utility : 0 kW

Pinch temperature : 75⁰C

Hot pinch temperature : 80°C

Cold pinch temperature : 70°C

As there is no requirement of cold utility the present problem is a threshold problem.

Let the temperatures of hot utility is from 190˚C to 189˚C. Thus, CP of hot utility is found as
114kW/˚C.
 Th5 Th6
200
Th4
180
Th2 Th3
160
Balanced hot composite curve
140
Tc6
temperature °C

120 Th1
Series1
100
Tc3 Tc4 and Tc5 series 2
80
Tc2
60
Tc1
Balanced cold composite curve
40 Show Tc1 to Tc6 in this figure

20

0
0 50 100 15
en0thalpy KW
2 00 250 300 350
ENTHALPY(kW)

Balanced hot and cold composite curve

The total heat transfer area is 68.866 m2. Now cost targeting can be described as -be

Capital cost = 30,000 + 400 (A) 0.9 = 30,000 + 400 (68.866)0.9 = 48041.156
Conversion of the capital cost into annual capital cost :
 i 1  i 
n
Conversion factor :
1  i n  1
where n and i are 5 and 10, respectively.

So the annual capital cost is computed as:

Annual capital cost = Capital cost * Conversion factor

0.1* 1  0.1
5
= 48041.156*
1  0.15  1

= 12673.1359 $yr -1

b)) Operating cost targeti

For the present problem hot and cold utility are found as 114 kW and 0 kW, respectively, as
computed for Problem 1 of Tutorial-03. Thus,

Hot utility cost = 114 * 120,000 = 13680.00 $.yr-1

Similarly,

Cold utility cost = 0 * 10,000 = 0 $.yr-1

Thus, total annual operating cost is 13680$.yr-1.

c)) Total Annual Cost AC) Targeting

TAC = Annual capital cost + Annual operating cost

=13680 +12673.1359 = 26353.1359

So, Total annual cost is targeted as $ 26353.1359/yr.