Process integration Heat exchanger network synthesis

Dr Ir Franois Marchal
LASSC (Laboratoire d'Analyse et de Synthse des Systmes Chimiques)

Universit de Lige
Sart-Tilman B6a B-4000 Lige Tl : 04 366 35 26 Fax : 04 366 35 25

Laboratioire dAnalyse et de Synthse des Systmes Chimiques Universit de Lige, Sart-Tilman B6a B 4000 Lige

E-mail : B.Kalitventzeff@ulg.ac.be Tel : + 32 4 366 35 21 Fax : + 32 4 366 35 25

FM_07/ 2000

Improve the MER :: onion structure Improve the MER onion structure
Chemical processes : the onion structure

Reaction Separation Utilities Heat exchanger network

Energy
Minimum Energy Requirements

Cost of Energy
Satisfy the energy requirement

Investments
Identify the energy saving heat exchanges

FM_07/ 2000

The process utilities The process utilities

Raw materials

Energy
Utilities Raw Utilities
Hot : fuels Cold : Cooling Water

Intermediate Utilities
Thermodynamic cycles Rankine , refrigeration, steam networks

Export

electricity

Process

Products and by-products

Waste

FM_07/ 2000

Engineering work method Engineering work method

From Goals & Constraints to Solutions ... From Goals & Constraints to Solutions ...
Goals & Constraints Goals & Constraints

Analyse Analyse
Problem definition Problem definition

Generate Generate
Results Results

Evaluate Evaluate
New problems - -New goals New problems New goals

Solutions Solutions

FM_07/ 2000

Utility integration Utility integration

Hot utility : above the pinch point
DH= Hot - Cold (KW) 0 60 2.5 60 62.5 80 82.5 Cascade (KW) 20

0 kW 60 kW

180 T (C) 160 140

? ?

DH= 60 kW DH= 60 kW DH= 2,5 kW DH= 2,5 kW 62,5 kW DH= -82,5 kW DH= -82,5 kW 0 kW Pinch point DH= 75 kW DH= 75 kW DH= -15 kW DH= -15 kW
90 Q(kW)

-82.5 -20 75 55 -15 40 60 75 0

Hot utility at 120 low T ! 20 kW 100

80 60 40 20 0 10 20 30 40 50 60 70

60 kW Cold utility at 15 kWhigher T ! 0 kW

80

Cold utility below the pinch point

FM_07/ 2000

Utility integration Utility integration

T(C)
220 200

Counter current analogy Hot utility -cold process

T T

Heat sink GCC ==cold stream GCC cold stream

180

P
160

Q
140

120

100

Self sufficient zones Self sufficient zones Exchange process -> process Exchange process -> process
D

80

GCC ==hot stream GCC hot stream

E F

Counter current analogy Hot process -cold utility

T T P

60

40

Heat source
0

200

600

H(kW)

FM_07/ 2000

Multiple utilities Multiple utilities

Identify the temperature levels
Qh min (C) T1

Q1

Q2

T2

T3

PINCH H (kW)

FM_07/ 2000

Multiple utilities Multiple utilities

Use of multiple utilities for different levels
T
T1
FU ME S

RAD

T2

HP

T3

LP

-> Cost of Energy instead of Energy -> Cost of Energy instead of Energy

FM_07/ 2000

Utilities
1100 T(K) 1000

900

800

700

Gas turbine ? Fuels ? Gas engines ? Enriched air ? Preheating ? Steam ?

Liquid Fuel ? Natural gas ? PSA ? VSA ? Membrane ? Cryogenic ? Temperature ? Pressure ? Turbine ? Compressor ? Absorption ?

600

500

400

300

200

Heat pumps ? Organic Rankine Cycles ? Water ? Refrigerant ? Pressure ? Air ?

0 2000 4000 6000 Q(kW)

refrigeration ?
10000 12000

Compressor ?

8000

FM_07/ 2000

Utility definition Utility definition

Type of utility T
(e.g. : combustion)

inlet conditions
(fuel type, combustion , operation)

Outlet conditions
(environment, operation)

H
33characteristics : : characteristics

- - H-T diagram (from GCC analysis) H-T diagram (from GCC analysis) - -Cost as aafunction of flowrate Cost as function of flowrate - -Flowrate : :to be determined to satisfy the Flowrate to be determined to satisfy the requirements at Minimum Costs. requirements at Minimum Costs.

FM_07/ 2000

Utilities definitions Utilities definitions

For the same MER !!! Utility 1 : C1 = cost 1 * flow 1
T(K) Q2

Different utility heat Different utility heat loads loads

Q1

Utility 2 : C2 = cost 2 * flow 2

Q(kW) -20 0 20 40 60

Energy available or excess Energy available or excess

FM_07/ 2000

Energy balance of a temperature interval

Integrating heat producers and consumers
Sharing energy by counter current heat exchange Excess of energy from the upper intervals

Ri+1
Energy for the hot streams in interval i

T* i+1

Energy for the cold streams in interval i

fj qji Ri

fj qji
T* i

Energy to the lower intervals

For each utility stream

Unknown flowrate-> Use YES/NO ? ->

fj

: Continuous variable

yj :Interger variable 1/0

FM_07/ 2000

Optimalisation
Minimum cost of energy requirement (MCER) Mixed Integer Linear Programming (MILP) min Ri, f j, yj Submit to : Heat balance nu Cost = ? C1jyj+ C2jf j j= 1
Hot stream j in interval i Cold stream j in interval i

(1)

nc Ri+ + ? fj qji 1 1 j= f min yj ? f j ,j

- ?

nf

f j qji - Ri =0 1 j=

(2)

Utility

f ma ,j yj x

2nd principle Ri? 0; R1=0; Rni+1=0 yj ?? ideal HEN model {0,1}

FM_07/ 2000

Combined mechanical power production

Linear constraints Mechanical power consumption nu ? ?w w fw ? w + Wel - Wp ? 0 w=1 Process requirement
Electricity import Production from the utilities(W w > 0 )

(3.1)

- Export of electricity Electricity export nu ? ? ww fw ? w + Wel - Welv - Wp = 0 w=1 - Operating cost buy nu Cost = ? (C1w y w + C2w fw ) + Cel Wel - Celv Welv Welv w=1 sell

(3.2)

(1)

FM_07/ 2000

Use of integer variables

1 integer variable for each flowrate
yj = 0 : the utility j is not used yj = 1 : the utility j is used

Linear constraint

f min,j yj ? f j ? fma ,jyj x if yj =0 => f min 0 ? f j ? f m x j 0 j is not selected ,j a, => 0 ? f j ? 0 => f j =0 j is selected if yj =1 => fmin ? f j ? f ma ,j ,j x Costj = C1j yj + C2j f j

Linear cost :

j is not selected j is selected

if yj =0=> Costj = C1j 0 + C2j 0 =0 if yj =1=> Costj = C1j + C2j f j

FM_07/ 2000

Results : balanced hot and cold composite curves

T(K) 1100 1000 900 800 700 600 500
steam consumption exothermal reactor steam production

Multiple pinch points optimal use of the cheapest utility

combustion

400 300 200 0

water cooling Air cooling

5000

10000

15000 20000 Q(kW)

25000

30000

35000

FM_07/ 2000

Balanced Grand composite curve

T(K) 1100 1000 900 800 700 600 500 400 300 200 0 1000 2000 3000 4000 Q(kW) 5000 6000 7000 8000

Understand the results ?

FM_07/ 2000

Evaluate : the Integrated Composite Curves

Hot and cold streams Sub-set A
n k n Aw r=k w=1 nA
i=1

Sub-set B : complement
n k n Bw r=k w=1 nB
i=1

RB k = R re f + ? ( ? f w q wr + ? Q ir )

RA k = Rref - ? ( ? f w q wr + ? Q ir ) - Rn k +1

T
n k n Bw r=kp w=1 nB
i=1

RB kp = 0 => Rref = - ? ( ? f w q wr +? Qir )

Q

FM_07/ 2000

ICC for utility system integration

T(K) 1100 1000 900 800 700 600 500 400 300 200 -2000 0 Process Utility system

Furnace

air cooling
2000 4000 6000 Q(kW) 8000

water
10000

fridge 12000

14000

FM_07/ 2000

ICC for the integration of the fumes

T(K) 1100 1000 900 800 700 600 500 400 300 200 -1000 0 1000 2000 3000 Q(kW) 4000 5000 6000 7000 Other systems Furnace

Excess of heat in the fumes

FM_07/ 2000

ICC for refrigeration cycle integration

T(K) 1100 1000 900 800 700 600 500 400 300 200 -1000 0 1000 2000 3000 4000 5000 Q(kW) 6000 7000 8000 "process" "Fridge system"

FM_07/ 2000

ICC of the steam network

T(K) 1100 1000 900 800 700 600 500 400 300 200 -1000 0 1000 2000 3000 4000 5000 6000 7000 8000 Q(kW) Other systems Steam network

Energy supplement

Steam production Steam cons.

Mechanical production
FM_07/ 2000

Heat exchanger placement audit

Systematic drawing of the ICC of the existing heat exchangers Heat exchange through the pinch point
700 650 600 550 500 T(K) 450 400 350 300 250 -2000 0 2000 4000 6000 Q(kW) 8000 10000 12000
Rest of the process cf remaining problem

Penality

MER Existing Heat Exchanger

FM_07/ 2000

Heat exchanger placement audit

Heat exchanger below the pinch point
600
T(K) MER

550 500
Penalty of heat exchanger

450 400 350 300 250 -1000

Remaining Q(kW) Heat exchanger Overall process

-500

500

1000

1500

2000

2500

3000

FM_07/ 2000

Conclusions
Method for targeting Minimum Cost of Energy Requirements

Analyse
using composite curves

Generate
using Mixed Integer Linear Programming

Evaluate
using a new graphical representation: the Integrated Composite Curves Better Understanding of the Integration of the components of the system
processes - utilities - steam network - heat exchangers

Support to the engineers creativity

FM_07/ 2000

HEN synthesis :: Introduction HEN synthesis Introduction

Chemical processes : the onion structure

Reaction Separation Utilities Heat exchanger network

List of streams

Investments

FM_07/ 2000

Heat exchangers network synthesis Heat exchangers network synthesis

Goals Goals Find a heat exchangers network that satisfies: - the MER and MCER - Minimum number of units or minimum of HTX modifications - Minimum investment - Other criteria - Best return on investment In other words ... In other words ... --Which hot stream with which cold stream ? Which hot stream with which cold stream ? --What is the heat exchanged ? What is the heat exchanged ? --What is the structure ::serial or //, ... What is the structure serial or //, ...
FM_07/ 2000

Heat exchanger network synthesis

Knowing ...
Target list of streams utility streams flow DTmin Hot and cold streams matching constraints Heat exchanger network Heat exchanger network structure
hot and cold streams in a heat exchanger heat load // or serie type and rating flowrates area and investment

Generate

Heat exchanger characteristic

Optimisation

Evaluate

Solutions benefit / investment detailled calculations

rating simulation operating conditions
FM_07/ 2000

Synthesis : methods
Heuristic Pinch design method
sequential Based on pinch location Sub-systems Feasibility rules Heuristic rules tick-off driving force work method loops energy relaxation

Mathematical programming Heat load distribution

with and without MER and DTmin multiple solutions Y/N integer variables

Superstructures
MINLP unimodality ?

Poor interaction of the engineer

Optimal ?

FM_07/ 2000

Heat exchangers network representation Heat exchangers network representation

Grid representation :

- Streams = horizontals - Heat exchange = verticals

60 50 60 50 20 30 25 35

9080 9080 80 90 70 80 80 70 70 80 8070 140 150 135 125

CP 2.5 Hot streams 3 2

110 100

Hot stream

2 1

Hot streams

Cold streams

Cold stream

Cold streams

Pinch Corrected temperatures Actual temperatures

Pinch

Pinch (a) (b) Pinch exchangers Pinch exchangers

FM_07/ 2000

Pinch design method :: feasibility rules Pinch design method feasibility rules
Numbers of streams Numbers of streams
80 2 80 3 ? 1 80 135 Cold stream 1 80 Pinch 135 Cold stream Below 90 140 Hot streams 2 80 3 80 90 140 Hot streams

For pinch exchangers Above the pinch point: Number of hot ? Number of cold the pinch point: Number of cold ? Number of hot

Pinch

Cp rule Cp rule
T 1 CPh DTmin 1 CPc Q Pinch CPh? CPc CPc

for pinch exchangers: Above the pinch point: Below the pinch point:

Cp hot ? Cp cold Cp cold ? Cp hot

FM_07/ 2000

Pinch Design Method :: heuristic rules Pinch Design Method heuristic rules
Goals :: Goals
- -Above the pinch point: cool down the hot streams without cold utilities. Above the pinch point: cool down the hot streams without cold utilities. - -Below the pinch point : :heat up the cold streams without hot utilities. Below the pinch point heat up the cold streams without hot utilities.

Start with pinch exchangers Rules Rules

1 - Order the streams by decreasing Cp

-> exchange first between the highest Cp

2 - The heat load is calculated to satisfy the heat load of one of the two stream involved : "tick-off" 3 - Place the utilities at the end of the streams

FM_07/ 2000

Pinch Design Method: Pinch Design Method: Remaining problem analysis Remaining problem analysis
Initial problem: Hot stream : Tic -> Toc Cold stream: Tif -> Tof Place a heat exchanger Toc T1 T4
Remaining problem Hot streams: Tic -> T2 : T1 -> Toc Cold streams: Tif -> T4 : T3 -> Tof

Tic T2 T3 Tof

Tif

New target
FM_07/ 2000

The synthesis algorithm The synthesis algorithm

Stream definition N{k} ? N{k-1} yes CP{k} ? CP{k-1} For pinch point connexion yes no All the possible connections are examined ? yes Place the exchanger and apply the tick -off rule to calculate its heat load. Remaining problem analysis no split {k} stream no Split {k -1} stream

Accept the connexion ? yes no suppress a connexion

{k} ordered list of Key streams with decreasing Cp at the pinch point {k-1} the other streams Key streams : Above the pinch point : hot streams Below the pinch point : cold streams
FM_07/ 2000

New data set

Pinch Design method :: Loops Pinch Design method Loops

Q3-X2 3 Q2-X2 C 1 2 Q4+X2 4 Q5+X2 5

Q2-X2

Q5+X2 H Q3-X2 Q4+X2

X2 = min(Q2,Q3,Q4,Q5) X2 = min(Q2,Q3,Q4,Q5) Suppress a heat exchanger ! Is the DTmin verified or acceptable ?

FM_07/ 2000

Pinch design method :: Energy relaxation Pinch design method Energy relaxation
Path following from hot utility to cold utility
3 Qc+X C Q1-X 1 2 4 5

H Q1-X Qh+X

X such that DTmin is verified X such that DTmin is verified If not => Energy Penalty !!!

FM_07/ 2000

HEN synthesis HEN synthesis

Draw backs of the simplified algorithm: Draw backs of the simplified algorithm: --multiple solutions multiple solutions --combinatorial problem combinatorial problem --sequential sequential

Use of mathematical programming: Use of mathematical programming: Heat load distribution: Heat load distribution: --which streams exchange heat which streams exchange heat --How much How much --minimize the number of connections minimize the number of connections --satisfies DTmin and MER satisfies DTmin and MER Remaining problem ::find the HEN structure Remaining problem find the HEN structure
FM_07/ 2000

Heat load distribution Heat load distribution

T*k+1 Qik T*k Hot stream i
Hot stream i in temperature interval k

Qikj Qikj Qikj

Qjk Qjk Qjk Cold streams j

nc

j=1

Q ikj = Q ik ? i = 1, ...,nh ; ? k = k1 ,...,k2

Cold stream j in and above temperature interval k

??
?
k2 r=k1

nh k2

j=1 r=k

Q irj - ? Q jr ? 0 ? j = 1 ,..., nc ; ? k = k1 ,..., k2

r=k

k2

connection between i et j (integer variable) Q irj - y ij Qmax ij ? 0 ? j = 1, ...,nc ; ? i=1, ...,nh

FM_07/ 2000

Heat load distribution Heat load distribution

MILP formulation MILP formulation

Minimize the number of connections Minimize the number of connections Min nh nc ? ? y ij y ij, Q ikj j=1 i=1

? Q ikj
j=1

nc

= Q ik ? i = 1, ...,nh ; ? k = k1 ,...,k2

?? ?
k2 r=k1

nh k2

j=1 r=k

Q irj - ? Q jr ? 0 ? j = 1 ,..., nc ; ? k = k1 ,..., k2

r=k

k2

Q irj - y ij Qmax ij ? 0

? j = 1, ...,nc ; ? i=1, ...,nh

FM_07/ 2000

The synthesis method The synthesis method

Calculate the heat load distribution for each section

Multiple solutions using integer cuts Heuristic rules or user -> screening and choice of the appropriate solution
Define the HEN structure

Apply feasibility rules and heuristics of pinch design method Splits and serial exchanges
Optimise the HEN

Total cost criteria no DTmin nor MER fixed

FM_07/ 2000

Heat exchanger network retrofit

Goals Reach the MER but Reuse existing system
reuse existing heat exchangers keep it in place if possible disconnect a minimum (minimise piping) increase area if necessary

Minimise process modifications Minimise investment

equipment operation

Trade-off Energy - Capital - Operation

FM_07/ 2000

Heat exchange network retrofit

1) Identify penalty exchangers
C1 3 C2 2 4 1

2) disconnect but remember ...

C1 3 C2 2 4 1

2
700 650 600 550 500 T(K) 450 400 350 300 250 -2000 0 2000 4000 Q(kW) 6000 8000 10000 12000

Heat exchange through the pinch point

Penality
MER Existing Heat Exchanger

H1

H1
Rest of the process cf remaining problem

PINCH

PINCH

FM_07/ 2000

Heat Exchanger network retrofit

1) Identify exchanger creating penalty 2) Eliminate these exchangers but remember of their position 3) Using the pinch design method, complete the network by utilising where possible the existing exchanger. The eliminated exchangers can be reused
in an other place if possible keep their place unless for one of the stream. existing exchangers can be by-passed to allow better exchange somewhere else.

4) Try to restore the existing area to decrease the investment The MER can be relaxed for this step to reuse the existing heat exchangers
heat sent through the loops heat sent through down stream path.
FM_07/ 2000

Optimize the heat exchangers network Optimize the heat exchangers network
NLP problem NLP problem Min nutil (C1 i + C2 i
X
nunit

i=1

f i)+ taux

i=1

(a i + b i A i i)

T1o T2i

L L

L-V L L-V

V L V A3 L

T1i T2o T1i T2o

Constraints
Heat and mass balances Rating equations Specifications :

L T1o

F(X) = 0
Bounds and limits

A2 A1 T2i L L

G(X) ? 0
X : State variables: pressure, temperature, area, heat
exchanged, ...

A=

n Qi Ai= ? ? i=1 i=1UDTlmi

Off course forget DTmin and MER constraints

FM_07/ 2000

Restricted matches constraints

Why ? Safety - product quality Topology Site scale and processes independence Existing approaches Cerda et al. (1983) - Papoulias and Grossmann (1983)
Energy target with constraints using large scale LP

Floudas - Grossmann and others

HEN superstructure together with energy target

Pinch technology
Restricted matches during the HEN synthesis

FM_07/ 2000

Restricted matches : our goals

Targeting the Minimum Cost Energy Requirement taking into account the restricted matches Energy penalty of the constraints ? Cost of the energy penalty ? Solve site scale problems Find technological solutions to minimise the cost penalty of the restricted matches
choice of the heat transfer fluids

Before the HEN synthesis task Start HEN synthesis with the complete list of streams

FM_07/ 2000

The heat cascade a LP formulation

minimise Rk

Rnk+1

Heat balance of a temperature interval nh nc Rk+1 + ? fi qik - Rk - ? fj qjk = 0 j=1 i=1 Rk ? 0

* ? (R k,Tk)

? k=1,...nk ? k=1,...nk +1

the MER heat cascade (Grand composite curve)

FM_07/ 2000

The constraints
Heat balance of a temperature interval nh nc ? k=1,...nk Rk+1 + ? fi qik - Rk - ? fj qjk = 0 j=1 i=1 Heat balance of a hot stream i in a restricted match ncai ? Qijk + Rik - fi qik - Rik+1 = 0 ? k=1,...,ki , ? i =1,...,nh j=1 Heat cascade of the cold stream j nh ? k=1,...,nk, ? j=1,...,nc ? Qijk ? fj qjk i=1 Overall heat cascade nh ? k=1,...,nk ? Rik ? Rk i=1

(1)

Accepted Matches Accepted Matches

(R1)

(R2)

(R3)

New variables

Rik ? 0 ? k=1,..., ki,? i =1,...,nh ; Rik+1 = 0 when k ? ki ; Qijk ? 0 ? k=1,..., nk,? i =1,...,nh, ? j=1,...,n c
FM_07/ 2000

Compute the energy penalty

Target the Minimum Cost Energy Requirement without constraints
Optimal heat cascade : R*k Fix the flowrates Add the restricted matches constraints Solve the problem (P1)

minimise Rnk+1 Rik , Qijk , Rk R nk+1 - R * nk+1 is the energy penalty

if penalty is acceptable goto HEN Synthesis if not choose the heat transfer fluid

FM_07/ 2000

Choose the heat transfer fluid

nh Rok =? ?Rik i=1 Restricted matches cascade Energy MER penalty 4807 kJ 6810 kJ
800 700

Grand composite curve

600

R hot 5250 kJ nh i=1

Heat sink Process pinch point Heat source

500

? ?Rik = Rk

400

300

200 -6000 -4000

-2000

Rcold 15600kJ 2000

4000

6000

8000

10000

12000

FM_07/ 2000

Heat transfer fluid characteristics

Process : Hot streams - - - Heat transfer fluid : cold stream - - - Heat transfer fluid hot stream Process : Cold streams

Conditions to be satisfied by the heat transfer fluid

1) 2) 3) All the Rk must be positive (definition of the MER); R nk+1 = R*nk+1 (no energy penalty is due to the use of the intermediate stream); Rok = Rk for all k =1,...,nk (the intermediate fluids solve the restricted matches constraints)

FM_07/ 2000

Choose the heat transfer fluid

Above the pinch point
900 T(K) 800 700

St e p 1 RMC Rhot 5250 kJ

St e p 2 Pr o c e s s GCC M ER 4807 kJ

St e p 3 Ne w GCC M ER 10057 kJ Rhot 5250 kJ

Heat from hot stream

600 500

400 300

Heat to cold stream

Co l d s t r e a m
200 0 2000 4000 0

Ad d c o l d stream
2000 4 0 0 0 0

Ho t s t r e a m
Q( k J ) 2000 4000 6000 8000
FM_07/ 2000

Choose the heat transfer fluid

Col d s t r e a m s 540 T(K) 520 500 480 460 440 420 400 380 360 -2000 -1000 0

Hot stream s

Rc o l d 1560 kJ

Rhot 5250 kJ 27.5 b

12 b 6 b

1.5 b

Energy penalty if 1. 5 b s t e a m i s u s e d
1000 2000 Q(kJ) 3000 4000 5000 6000

Place the heat transfer fluid between Red and Blue lines
FM_07/ 2000

Steam network and restricted matches

fuel

Process 1

Cooling system

C Process 2

FM_07/ 2000

Target the minimum cost of energy requirement

Add the heat transfer fluids Hot and cold streams Unknown flowrate Use the MILP model Heat cascade Mechanical power balance EMO models
Energy technologies Heat transfer fluids or steam network

Restricted matches constraints Objective function : Minimum Cost of Energy

Fuels - Electricity - CHP - Investments

SYNTHESIS with complete list of streams

FM_07/ 2000

Heat exchanger network synthesis

Any Questions ?

FM_07/ 2000