CEB4313 – PROCESS INTEGRATION
SYNYHESIS OF HEAT EXCHANGER
NETWORK (HEN)
Stream Splitting
Threshold Problems
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STREAM SPLITTING
Stream Splitting
Above Pinch
PINCH
CP
100° 12
1
100°
2 20
100° 7
3
T > 90 90°
4 15
T > 90 90°
5 30
What do we do?
Stream Splitting
Above Pinch
PINCH CP
1
100o 12
If the number of hot
100o
2 20
stream is greater than
3 100o 7 the number of cold
streams
90° 15
→ split the cold stream
4
90°
5 30
Stream Splitting
Above Pinch
Rule:
Above the pinch, NH ≤ NC
• NH = number of hot streams
• NC = number of cold streams
Stream Splitting
Below Pinch
PINCH
CP
100° T < 100
1 35
100° T < 100
2 60
90°
4 24
90°
5 30
90°
4 20
What do we do?
Stream Splitting
Below Pinch
PINCH CP
If the number of CP
100
o
cold stream is 35 1 35
greater than a
o
100
60 2 60
number of hot
streams
→ split the hot
stream 90o
24 4 24
90o
30 5 30
90o
20 6 20
Stream Splitting
Below Pinch
Rule:
Below the pinch, NH ≥ NC
• NH = number of hot streams
• NC = number of cold streams
Stream Splitting
Example: Below Pinch
NH ≥ NC
The CPH ≥ CPC
rules:
5 7
4
PINCH CP
100° 30°
1 5
100° 40°
2 4
No feasible
90° match! 15° 7
3
Stream Splitting
Example: Below Pinch
NH ≥ NC
CPH ≥ CPC
5 4
7
4 3
PINCH
50 kW CP Q
100° 40° 30°
1 C1 5 350
100° 43.75° 40° 4 240
2 C2
15 kW
4 300
15°
90° 300 kW 3 225
3 3
225 kW
Split cold stream
Stream Splitting
Choosing split ratio
What about ?
N H ≥ NC
CPH ≥ CPC
5 3.5
7
There is an
4 3.5
infinite number
or ? of split ratios !
NH ≥ NC
CPH ≥ CPC
5 4.5
7
4 2.5
Stream Splitting
Choosing split ratio
Save one unit by ticking off two streams at once.
PINCH
CP Q
65 kW
100° 43o 30°
1 C 5 350
100° 40 40° 4
2 240
C
3.8 285
90° 15°
285kW 3
3.2 240
240 kW
𝑄 = 𝐶𝑃 × ∆𝑇
4 100 − 40 = 𝐶𝑃𝐶1 90 − 15
𝐶𝑃𝐶1 = 3.2
Stream Splitting
Summary
Above Pinch
Stream data
at pinch
Yes Yes
CPH ≤ CPC NH ≤ NC
for Pinch
matches? ?
No
No
Split Cold
Stream
Split Hot
Stream
Place
Matches
Stream Splitting
Summary
Below Pinch
Stream data
at pinch
Yes Yes
CPH ≥ CPC NH ≥ NC
for Pinch
matches? ?
No
No
Split Hot
Stream
Split Cold
Stream
Place
Matches
Stream Splitting
Working Session 6
Stream data
Supply Target Heat Capacity
Stream Type Temperature Temperature Flow rate
TT (oC) TT (oC) (KW oC-1)
1 Hot 750 350 45
2 Hot 550 250 40
3 Cold 300 900 43
4 Cold 200 550 20
ΔTmin = 50 ºC
The pinch is at 550 ºC / 500 ºC
QHmin = 9200 QCmin = 6400
Design a network for maximum energy recovery
Stream Splitting
Working Session 6
Above Below
CP H≤ CP C CPH ≥ CPC
NH ≤ NC N ≥ NC
H
45 43 45 43
20 40 20
Duties above
PINCH
CP the Pinch
750° 550° 350°
45 1 9000kW
550°
250°
40 2
900° 500° 300°
43 3 17200 kW
550° 500° 200°
20 4 1000 kW
Stream Splitting
Working Session 6
Network Design
CP
CP=40
750o
550o 358.9o 350o
45 1 C
CP=5
400
550o 400o 250o
40 2 C
6000
900o 500o 300o
43 3 H
9200 8000 8600
550o 500o 200o
20 4
1000 6000
THRESHOLD PROBLEMS
Threshold problems
No integration
T
Steam
Worst case
scenario!
CW
ΔH
When no heat recovery is performed, there is need
for both hot and cold utilities
Threshold problems
Recovering heat
T Steam
ΔTmin
CW
ΔH
ΔTmin = 20ºC ► Process Heat Recovery
Threshold problems
Reducing ΔTmin: No Hot Utility
T
ΔTmin Reduced
CW
ΔH
ΔTmin = 14ºC ► More Process Heat Recovery
Threshold problems
Hot End
CW
ΔH
Threshold problems
Cold End
T
Steam
ΔH
Threshold problems
How to design the HEN
T ST
ΔH, MW
Treat exactly like a PINCH problem
HEN Design
Working Session 7
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
ΔTmin = 7 ºC
The pinch is at 67 ºC / 60 ºC
QHmin = 840 QCmin = 0
Design a Network for Maximum Energy Recovery
Complete Design
Maximum Energy Recovery Network
CP
180 º 80 º
1 3 20
130 º 67 º 40 º
2 2 1 40
100 º 91.5 º 60 ºC
H1 2 3 80
680 kW 2520 kW
120 º 115.6 º 60 º 30 º
H2 3 1 4 36
160 kW 2000 kW 1080 kW
