Ene-47.
5130 Process Integration (3 ECTS credits) P
Espoo 2016
EXERCISE 2 – SOLUTIONS
1 MER heat exchanger network
First we draw the stream-grid and calculate the enthalpy rate change, Q̇, above and below the
pinch for each stream.
pinch
180°C
cp*m = 3.5 80°C 60°C
Q = 350 1 Q = 70
140°C
cp*m = 1.5 80°C 30°C
Q = 90 2 Q = 75
45°C
115°C cp*m = 2.0 70°C
Q = 90 3 Q = 50
70°C
160°C cp*m = 5.0
Q = 450 4 Q=−
above the pinch below the pinch
According to the Euler method the minimum number of units: Umin,M ER = (N −
1)above + (N − 1)under = (5 − 1) + (4 − 1) = 7
above the pinch
To ensure that the driving forces are correct close to the pinch the following requirement must
be met for the cold and hot streams to be matched (cp · ṁ)cold ≥ (cp · ṁ)hot . The only way
this can be met is to match stream number 1 and 4 and stream number 2 and 3.
• cp4 · ṁ4 = 5.0 ≥ 3.5 = cp1 · ṁ1
• cp3 · ṁ3 = 2.0 ≥ 1.5 = cp2 · ṁ2
We want to cool both the hot streams to the pinch temperature. The next step is to find the
duty for the two heat exchangers:
• Q̇above
1,4 = min{350, 450} = 350 kW
• Q̇above
2,3 = min{90, 90} = 90 kW
Since there is not enough heat in stream 1 and 2 to heat stream 4 to the target temperature we
need to add a heater. In order to calculate the duty of the heater we need the temperature of
stream 4 after the heat exchanger:
350
T4 = 70 + = 140 ◦ C
5
The duty of the heater is then:
Q̇heater = 5.0 · (160 − 140) = 100kW
below the pinch
Below the pinch the requirement to ensure correct driving forces close to the pinch is:
(cp · ṁ)hot ≥ (cp · ṁ)cold
The only match meeting this requirement is stream 1 and 3. The duty of the heat exchanger
is then:
Q̇below
1,3 = min{70, 50} = 50kW
The exit temperature for stream 1 from the heat exchanger is then:
50
T1 = 80 − = 65.7 ◦ C
3.5
We now have only hot streams left below the pinch and these need to be cooled with coolers.
The duty of the coolers are then:
Q̇cooler,1 = 3.5 · (65.7 − 60) = 20kW
Q̇cooler,2 = 1.5 · (80 − 30) = 75kW
The heat exchanger network is shown in the drawing below.
pinch
180°C
80°C 65.7°C 60°C
1 C
Q = 20 kW
140°C
80°C 30°C
2 C
Q = 75 kW
45°C
115°C 70°C
3
Q = 90 kW Q = 50 kW
70°C
160°C
H 4
Q = 100 kW Q = 350 kW
above the pinch below the pinch
Note that the cooling and heating is the same as the targets found in Exercise 1). The reason
why the number of units above the pinch is less than the expected 5 − 1 = 4 is that we have a
perfect match between two streams. This results in two sub-networks above the pinch, so the
maximum number of units needed is: Uabove = 5 − 2 = 3.
2 Problem table algorithm
a)
First we must adjust the start and target temperatures. This is done by subtracting 12 ∆Tmin
from the hot streams’ temperatures and adding 12 ∆Tmin to the cold streams’ temperatures.
∆Tmin adjusted
stream # type cp · ṁ Tstart [◦ C] Ttarget [◦ C] Tstart [◦ C] Ttarget [◦ C]
1 hot 3.5 180 60 175 55
2 hot 1.5 140 30 135 25
3 cold 2.0 45 115 50 120
4 cold 5.0 70 160 75 165
b)
We can then draw the streams and identify the intervals:
175°C 1
165°C 5.0 kJ/Ks
135°C 2
2.0 kJ/Ks
120°C
75°C
4
55°C
3.5 kJ/Ks
50°C
3
25°C
1.5 kJ/Ks
interval [◦ C]
P P
hot cp · m − cp · m
cold surplus/deficit [kW ]
175–165 3.5 35.0
165–135 3.5 − 5.0 = −1.5 -45.0
135–120 3.5 + 1.5 − 5.0 = 0.0 0.0
120– 75 3.5 + 1.5 − 5.0 − 2.0 = −2.0 -90.0
75– 55 3.5 + 1.5 − 2.0 = 3.0 60.0
55– 50 1.5 − 2.0 = −0.5 -2.5
50– 25 1.5 37.5
c)
Based on this information we can draw a heat cascade diagram.
0.0 kW 100.0 kW
175 − 165°C 35.0 kW 35.0 kW
35.0 kW 135.0 kW
165 − 135°C −45.0 kW −45.0 kW
−10.0 kW 90.0 kW
135 − 120°C 0.0 kW 0.0 kW
−10.0 kW 90.0 kW
120 − 75°C −90.0 kW −90.0 kW
−100.0 kW 0.0 kW
75 − 55°C 60.0 kW 60.0 kW
−40.0 kW 60.0 kW
55 − 50°C −2.5 kW −2.5 kW
−42.5 kW 57.5 kW
50 − 25°C 37.5 kW 37.5 kW
−5.0 kW 95.0 kW
Heat can be transfered from a higher temperature to a lower, but not vice versa. A negative
heat flow is not feasible since it would mean a heat transfer from a low temperature to a high.
Looking at the cascade we can identify the largest thermodynamic in-feasibility, which in this
case is 100 kW . We can make it thermodynamically feasible by adding this amount of heat
to the top of the cascade.
The minimum utility consumptions and the pinch temperature can be directly read from
this cascade. In this case the minimum hot- and cold utility consumption is 100 kW and
95 kW respectively and the pinch temperature is 75 ◦ C. The pinch temperature is found
where no heat is cascaded.
3 HINT
a)
200
180
160
140
120
T (°C)
100
80
60
40
20
0
0 20 40 60 80 100 120 140 160
Q (kW)
b)
First we must remember to adjust for ∆Tmin , which means that the high- and low pressure
steams adjusted temperatures are 185 ◦ C and 125 ◦ C respectively. The total minimum hot
utility consumption is 100 kW . We are able use 90 kW low pressure steam. This leaves
10 kW for high pressure steam. The grand composite curve is shown in the figure below.
high pressure steam
190
180
170
160
150
140
130 low pressure steam
120
110
100
T (°C)
90
80
70
60
50
40
30
20
10
0
0 20 40 60 80 100 120 140 160
Q (kW)
4 Heat pump
a)
First we must adjust the temperatures for ∆Tmin . Then we check how much heat that is
available for the evaporator (at 65 ◦ C). We can get approximately 30 kW for the evaporator.
This corresponds to 45 kW heat from the condenser;
QC COP
COP ≈ ⇒ QC = · QE
QC − QE COP − 1
3
QC = · 30 = 45
3−1
This means that with help of the heat pump we can reduce the low pressure steam con-
sumption with 45 kW and the cooling water consumption with 30 kW . The electricity
consumption for the heat pump is 15 kW .
b)
200
190
180
170
160
150
140
130
condenser
120
110
T (°C)
100
90
80
70
60
evaporator
50
40
30
20
10
0
0 20 40 60 80 100 120 140 160
Q (kW)
