Adigrat University
College of Engineering and Technology
Department of Chemical Engineering
Process Integration and Optimization
Part I: Process Integration
Lecture 2
Andom M.
Targets for Energy Recovery
The Target of any industrial process designer is to maximize
the process-to process heat recovery and to minimize the
utility (energy) requirements.
To meet the goal of maximum energy recovery or minimum
energy requirement (MER) an appropriate heat exchanger
network (HEN) is required.
…Cont’d
Selection of Initial ΔTmin value
A few values of ΔTmin based on Linnhoff March’s application
experience are tabulated below for shell and tube heat exchangers.
Table1. Typical ΔTmin values
Composite Curves
Composite curves were developed for heat recovery
targeting (Linnhoff et al., 1982).
One hot composite stream represents all the hot process
streams, while one cold composite stream represents all the
cold process streams.
In essence, the hot composite stream represents a single
process heat source, while the cold composite stream
represents a single process heat sink.
…Cont’d
Combined Composite Curves are used to predict targets for;
Minimum energy (both hot and cold utility) required.
Minimum network area required, and
Minimum number of exchanger units required.
ΔTmin can be measured directly from the T-H profiles as being
the minimum vertical difference between the hot and cold
curves. This point of minimum temperature difference
represents a bottleneck in heat recovery and is commonly
referred to as the “Pinch”
…Cont’d
Reading accurate information from such diagrams can be
somewhat difficult, which is why numerical methods are
often preferred.
The real advantage of such graphical diagrams, however,
is that they provide an overview of the system and they
contribute strongly to the understanding of the problem.
…Cont’d
Stream Data
The stream data chosen to illustrate the construction of the
Composite Curves. The following minimum elements are
necessary: Stream or segment temperatures are: Supply TS℃,
and Target TT℃.
𝐾𝑊
Heat capacity flow rate (CP ℃
):the product of FxCP (mass
flow rate Kg/sec by the mass heat capacity KJ/Kg℃)
CP= ∆H
∆T
Where: ∆H is the enthalpy variation over the temperature
interval ∆T. Conversely, Enthalpy Change (∆H) associated with
a steam passing through the exchanger is given by first law of
thermodynamics.
…Cont’d
First law energy equation: H = Q ± W
In a heat exchanger no mechanical work is being performed
W=0
The above equation simplified to: H = Q where Q represent the
heat supply or demand associated with the stream .
It is given by the relationship Q = CP × (TT − TS)
Enthalpy Change, ∆H = CP × (TT − TS)…………… Eq
Temperature-Enthalpy (T - H) Diagrams
Assume one heat These are alternative
exchanger. representations
…Cont’d
Assume one heat exchanger and a heater
…Cont’d
Assume one heat exchanger and a cooler
…Cont’d
Two hot-one cold stream
…Cont’d
…Cont’d
Moving composite curves horizontally
…Cont’d
…Cont’d
Graphical Procedure
Fix ΔTmin (HRAT)
Draw the hot composite curve and leave it fixed
Draw the cold composite curve in such a way that the smallest
temperature difference is equal to ΔTmin
The temperature at which ΔT = ΔTmin is the PINCH
The non-overlap on the right is the Minimum Heating Utility
and the non-overlap on the left is the Minimum Cooling Utility
Show below Example ∆Tmin 10℃
…Cont’d
Stream Type F*CP
Reactor 1 feed Cold 20 180 32.0 0.2
Reactor 1 product Hot 250 40 -31.5 0.15
Reactor 2 feed Cold 140 230 27.0 0.3
Reactor 2 product Hot 200 80 -30.0 0.25
…Cont’d
…Cont’d
…Cont’d
Problem Table Algorithm for minimum utility calculations
Graphical constructions are not the most convenient means
of determining energy needs.
A numerical approach called “Problem Table Algorithm”
PTA was developed by Linnhoff & Flower (1978) as a means
of determining the utility needs of process and the location
of the process Pinch.
The PTA lends itself to hand calculations of the energy
targets.
…Cont’d
Example 1: ∆Tmin 10℃
Stream Type F*CP
Reactor 1 feed Cold 20 180 32.0 0.2
Reactor 1 product Hot 250 40 -31.5 0.15
Reactor 2 feed Cold 140 230 27.0 0.3
Reactor 2 product Hot 200 80 -30.0 0.25
…Cont’d
Procedures:
1. Convert the actual stream TO (Tact) into interval TO (Tint) by
subtracting half the minimum temperature difference from the hot
stream temperatures, and by adding half to the cold stream
temperatures:
Hot streams Tint = Tact − ∆𝑻𝒎𝒊𝒏
𝟐
Cold streams Tint = Tact + ∆𝑻𝒎𝒊𝒏
𝟐
2. Note any duplicated interval temperatures. These are bracketed
…Cont’d
3. Rank the interval temperatures in order of magnitude, showing the
duplicated temperatures only once in the order
4.Carry out a heat balance for the streams falling within each
temperature interval: For the nth interval
5. "Cascade" the heat surplus from one interval to the next down the
column of interval temperatures
Cascading the heat from one interval to the next implies that the
temperature difference is such that the heat can be transferred
between the hot and cold streams.
…Cont’d
The presence of a negative value in the column indicates that the
temperature gradient is in the wrong direction and that the
exchange is not thermodynamically possible.
This difficulty can be overcome if heat is introduced into the top
of the cascade.
Introduce just enough heat to the top of the cascade to eliminate
all the negative values
…Cont’d
Or cascade diagram illustrates the amounts of available energy, in
excess of that required by process streams, at each temperature
level in the temperature interval diagram.
The cascade diagram is useful for visualizing how excess energy
is cascaded downwards to heat lower temperature streams.
It is also useful for identifying where the network pinch occurs.
…Cont’d
Step 1: Convert the actual temperature in to interval temperature (Tint)
Tact Tint
Cold 20 180 25 185
Hot 250 40 245 35
Cold 140 230 145 235
Hot 200 80 195 75
Step 2: Note any duplicated interval temperature. These are bracketed
…Cont’d
Step 3: Rank the interval temperatures in order of magnitude,
showing the duplicated temperatures only once in the order
Grid Diagram
…Cont’d
Step 4. Carry out a heat balance for the streams falling within each
temperature interval: For the nth interval.
…Cont’d
Cascade the heat surplus from one interval to the next
down the column of interval temperature
245……………0Kw(-)…………………………………………………………………..7.5Kw (+)
235……………..-1.5………………..1.5…………………………………………………….9
195……………..6.0………………..-4.5………………………………………………..…..3
185…………....-1.0……………....-3.5…………………………………………………....4
145……………….4.0……………….-7.5…………………………………………………...0
75...................-14…………...…..6.5…………………………………………………..14
35………………...2.0……………..…4.5…………………………………………………..12
25………………….2.0…………….…2.5…………………………………………………..10
…Cont’d
…Cont’d
Exercise:
TheEnd of Lecture2!!!
