CPE 614
Process Integration
CHAPTER 4
Capital Cost Considerations
Dr Nurul Haiza Sapiee
Process Integration
1 2 3 4 5 6 7
Introduction, Energy Targets Heat Exchanger Optimization of Process Utility Heat Water Pinch
Overview & Network for Heat Exchanger System Integration Analysis
Basic Maximum Network and
Terminology Recovery Total Cost
CPE 614 Process Integration 2
COURSE LEARNING Outcome
CHAPTER 4 LEARNING OUTCOME (CO2, PO5)
• Understand what contributes to the total costs and how to optimize it
• Understand the difference between capital costs and energy costs
• Understand how to minimize number of HE units using loop breaking and path relaxation
CPE 614 Process Integration 3
CAPITAL ENERGY trade-offs
• Recovery of heat from a waste steam involves a trade-off between reduced energy cost and
increased capital cost of heat exchanger
• The correct setting for ∆Tmin is economical
• Energy cost is a function of ∆Tmin
Chapter 4 4
Heat recovery vs cost trade offs
Chapter 4 5
Cost Variation with ΔTMin
• There is usually an optimal value of ΔTmin
• The optimal ΔTmin is correlated to the smallest total cost
• This is usually related with the smallest heat exchanger area
Chapter 4 6
Capital costs
Area
Pressure Number of
rating units
Capital
Cost
Equipment Number of
type shells
Materials of
construction
Chapter 4 7
Minimum Number of Heat
PART 1 Exchanger Units
October 2023 Chapter 4 8
Loop Breaking & Path rELAXATION
Steps to reduce the number of heat exchanger units using loop & path
1. Extract and complete stream data
2. Use CC/ PTA to get Tpinch and energy targets
3. Design a HEN for maximum energy recovery
4. Find the loop to enable heat load shift
5. Find smallest HE in the loop and eliminate it
6. Check ΔTmin violation, find ΔT in the loop
7. Find path to shift heat loads
8. Correct ΔTmin violation
9. Finalize the heat load and number of units
Chapter 4 9
Loop
• A circular path that exists among exchangers that enables a heat load shift
• A set of connections that can be traced through a network that starts at one exchanger and
returns to the same exchanger
• Usually will pass through the pinch
• We can remove the smallest heat exchanger in the loop
Chapter 4 10
Loop
Chapter 4 11
Loop
Chapter 4 12
PATH
• Connects a heat exchanger between two utilities
• Heat load can be shifted along the path
• Connection between a heater & cooler in a network
• To correct ΔTmin violation
Chapter 4 13
PATH
Chapter 4 14
EXAMPLE
Simplify the structure of this HEN by reducing the number of units.
CP Pinch
(kW/0C)
1000kW o
250oC 203.3oC 150oC 106.7oC 40 C
15 2 C
200oC 150oC 80oC
25 4
180oC 140oC 52.5oC 20oC
20 1
800kW 1750kW 650kW
230oC 205oC 181.7oC 140oC
30 H 3
750kW 700kW 1250kW
Chapter 4 15
Step 4: Find the loop to enable heat load shift
Chapter 4 16
Step 5: Find smallest HE in the loop and eliminate it
Chapter 4 17
Step 6: Check ΔTmin violation, find ΔT in the loop
Chapter 4 18
Step 6: Check feasibility
Chapter 4 19
Step 7: Find path to shift heat loads
Chapter 4 20
Step 8: Correct ΔTmin violation and shift loads
Chapter 4 21
Step 9: Finalize the heat load and number of units
Chapter 4 22
ANOTHER LOOP! (Always check for more loops)
Chapter 4 23
Step 5: Find smallest HE in the loop and eliminate it
Chapter 4 24
Step 6: Check ΔTmin violation, find T in the loop
Chapter 4 25
Step 6: Check feasibility
Chapter 4 26
SOLUTION : Final Answer
CP
(kW/0C)
250oC 117.5oC 40oC
15 2 C
Methods Before After
1162.5kW
200oC 128.5oC 80oC
25 4 Loop
180oC 80.625oC 20oC
20 1 Path
1987.5kW 1212.5kW
230oC 199.6oC 140oC
30 H 3
912.5kW 1787.5kW
Chapter 4 27
Conclusions
• Importance of using the best ΔTMin from trade-off
• Loop breaking & path relaxation can reduce the number of HE units
• There will be some increase in utilities to balance out the loads
• Degrees of freedom in the design can help optimize HEN
Chapter 4 28
Thank you Any questions?
October 2023 Dr Nurul Haiza Sapiee 29
