Heat exchanger network II Heat exchanger network II Heat exchanger network II Heat exchanger network II

Problem Table Algorithm & Grand Problem Table Algorithm & Grand Problem Table Algorithm & Grand Problem Table Algorithm & Grand
Composite Curve Composite Curve Composite Curve Composite Curve
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 2
Lecture outline Lecture outline Lecture outline Lecture outline
Problem table algorithm
1. Shifted temperature
2. Energy balance
3. Heat cascade
Grand composite curve (GCC)
Utility selection & steam
generation with GCC
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 3
The composite curves The composite curves The composite curves The composite curves
H (MW)
T (C)
T
min
Pinch
Q
Hmin
Q
Cmin
Heat
sink
Heat
source
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 4
Its limitation & alternative Its limitation & alternative Its limitation & alternative Its limitation & alternative
Limitation of composite curves
Graphical construction inconvenient
Inaccuracy
Computational ineffective
Software interaction is limited
Another targeting tool the problem table
algorithm(PTA)
Numerical alternative to locate energy targets
Accurate and rapid
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 5
The basic principles of PTA The basic principles of PTA The basic principles of PTA The basic principles of PTA
If the composite curve is divided into temperature intervals, driving
forces are not feasible throughout the interval.
Some heat recovery is possible, but not all heat can be recovered
This problem can be overcome if:
Hot composite is shifted T
min
/2 colder than it is in practice
Cold composite is shifted T
min
/2 hotter than it is in practice
The shifted composite curves will touch at the pinch
Note: shifting is just for the sake of PTA calculation, no actual shifting!
H
T
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 6
Calculation steps Calculation steps Calculation steps Calculation steps
1. Set up shifted temperature intervals from original
stream T
S
& T
T
values:
Hot stream: subtract T
min
/2 to make it colder
Cold stream: add T
min
/2 to make it hotter
2. Calculate energy balance in each shifted
temperature intervals i:
If hot stream dominate: H in +ve heat surplus
If cold stream dominate: H in -ve heat deficit
3. Cascade the heat down the temperature interval,
provide external hot utility if needed
i i
T CP CP H

=

Cold
C
Hot
H
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 7
Back to the previous example Back to the previous example Back to the previous example Back to the previous example
Steam Type
Supply
temp,
T
S
(C)
Target
temp,
T
T
(C)
H
(MW)
Heat capacity
flowrate, CP
(MW.K
-1
)
1. Reactor 1 feed Cold 20 180 32.0 0.20
2. Reactor 1 product Hot 250 40 31.5 0.15
3. Reactor 2 feed Cold 140 230 27.0 0.30
4. Reactor 2 product Hot 200 80 30.0 0.25
Reactor 1
Feed 1
20C
Reactor 2
Feed 2
140C
Off gas, 40C
Product 1, 40C
180C
40C
250C
230C 200C Product 2
80C
Note: Heat capacity flowrate, CP = m.C
p
( )
S T p p
T T mC T mC Q = =
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 8
PTA Step 1 PTA Step 1 PTA Step 1 PTA Step 1 Shifted T intervals Shifted T intervals Shifted T intervals Shifted T intervals
Set up shifted temperature intervals from original stream
T
S
& T
T
values:
Hot stream: subtract T
min
/2 to make it colder
Cold stream: add T
min
/2 to make it hotter
T
min
= 10C
Stream Type T
S
T
T
T
*
S
T
*
T
1 Cold 20 180 25 185
2 Hot 250 40 245 35
3 Cold 140 230 145 235
4 Hot 200 80 195 75
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 9
PTA Step 1 PTA Step 1 PTA Step 1 PTA Step 1 Shifted T intervals Shifted T intervals Shifted T intervals Shifted T intervals
245
Shift temp
interval, T* (C)
235
195
185
145
75
35
25
C1
C3
H2
H4
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 10
PTA Step 2 PTA Step 2 PTA Step 2 PTA Step 2 H balance H balance H balance H balance
T* (C) Stream population T* CP
H
- CP
C
H
Surplus/
Deficit
245
235
195
185
145
75
35
25
10 0.15 1.5 Surplus
40 -0.15 -6.0 Deficit
10 0.1 1.0 Surplus
40 -0.1 -4.0 Deficit
70 0.2 14.0 Surplus
40 -0.05 -2.0 Deficit
10 -0.2 -2.0 Deficit
C1
C3
H2
H4
C
P

=

0
.
2
C
P

=

0
.
1
5
C
P

=

0
.
3
C
P

=

0
.
2
5
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 11
PTA Step 3 PTA Step 3 PTA Step 3 PTA Step 3 Heat cascade Heat cascade Heat cascade Heat cascade
245
235
195
185
145
75
35
25
H = 1.5
H = -6.0
H = 1.0
H = -4.0
H = 14.0
H = -2.0
H = -2.0
Cold utility
Hot utility
0 MW
1.5 MW
-4.5 MW
-3.5 MW
-7.5 MW
6.5 MW
4.5 MW
2.5 MW
245
235
195
185
145
75
35
25
H = 1.5
H = -6.0
H = 1.0
H = -4.0
H = 14.0
H = -2.0
H = -2.0
Cold utility
Hot utility
7.5 MW
9.0 MW
3.0 MW
4.0 MW
0 MW
14 MW
12.0 MW
10.0 MW
Negative heat
cascade
infeasible (heat
is transferred
from lower to
higher temp)
Largest heat
deficit
Pinch temp:
Hot stream = 145+5 = 150C
Cold stream = 1455 =140C
Q
Hmin
=
Q
Cmin
=
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 12
Match values obtained from CC Match values obtained from CC Match values obtained from CC Match values obtained from CC
H (MW)
T (C)
Q
REC
= 51.1 Q
Hmin
= 7.5 Q
Cmin
= 10
T
min
= 10C
Pinch
230
20
250
40
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 13
Heat cascade & shifted CC Heat cascade & shifted CC Heat cascade & shifted CC Heat cascade & shifted CC
H
T
Q
Hmin
Q
Cmin
Shifted
composite
curves
Cold composite
when Q
Hmin
= 0
Maximum
overlap
H
T
Q
Hmin
Q
Cmin
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 14
Working session Working session Working session Working session
Calculate the hot & cold utility requirements and the pinch
location
Assuming T
min
= 5C
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 19
Practice makes perf Practice makes perf Practice makes perf Practice makes perfect! ect! ect! ect!
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 20
Convention of Convention of Convention of Convention of H in Step 2 H in Step 2 H in Step 2 H in Step 2
Conventional Process Integration books (Linnhoff
et al., 1982; Smith, 1995, 2005) follow standard
thermodynamics convention
Energy balance calculation in Step 2:
If cold stream dominate: H in +ve heat deficit
If hot stream dominate: H in -ve heat surplus
Consistent with H
R
of exothermic reaction in
positive value
All calculation steps remain the same
i i
T CP CP H

=

Hot
H
Cold
C
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 21
Alternative heat cascading Alternative heat cascading Alternative heat cascading Alternative heat cascading
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 22
Composite Curve Composite Curve Composite Curve Composite Curve
Q
Hmin
= 7.5
Q
Cmin
= 10
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 23
Network to achieve the targets Network to achieve the targets Network to achieve the targets Network to achieve the targets
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 24
In conventional PDF In conventional PDF In conventional PDF In conventional PDF
Network design is not our concern
now, we will learn how to design the
network 2 weeks from now.
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 25
The The The The Onion diagram Onion diagram Onion diagram Onion diagram
Reactor
Separation &
recycle
Heat exchanger
network
Utilities
(Linnhoff et al., 1982;
Smith, 1995, 2005)
We are
finally here
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 26
Hot Utility Systems Hot Utility Systems Hot Utility Systems Hot Utility Systems
Stream system
Hot oil system
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 27
Cold Utility Systems Cold Utility Systems Cold Utility Systems Cold Utility Systems
Cooling water
system
Refrigeration
system
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 28
Back to the previous example Back to the previous example Back to the previous example Back to the previous example
Steam Type
Supply
temp,
T
S
(C)
Target
temp,
T
T
(C)
H
(MW)
Heat capacity
flowrate, CP
(MW.K
-1
)
1. Reactor 1 feed Cold 20 180 32.0 0.20
2. Reactor 1 product Hot 250 40 31.5 0.15
3. Reactor 2 feed Cold 140 230 27.0 0.30
4. Reactor 2 product Hot 200 80 30.0 0.25
Reactor 1
Feed 1
20C
Reactor 2
Feed 2
140C
Off gas, 40C
Product 1, 40C
180C
40C
250C
230C 200C Product 2
80C
Note: Heat capacity flowrate, CP = m.C
p
( )
S T p p
T T mC T mC Q = =
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 29
Grand composite curve (GCC) Grand composite curve (GCC) Grand composite curve (GCC) Grand composite curve (GCC)
245
235
195
185
145
75
35
25
H = 1.5
H = -6.0
H = 1.0
H = -4.0
H = 14.0
H = -2.0
H = -2.0
Cold utility
Hot utility
7.5 MW
9.5 MW
3.0 MW
4.0 MW
0 MW
14 MW
12.0 MW
10.0 MW
H (MW)
Pinch
Shift temp, T* (C)
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 30
Grand composite curve (GCC) Grand composite curve (GCC) Grand composite curve (GCC) Grand composite curve (GCC)
H (MW)
Pinch
Shift temp,
T* (C)
145
Q
Hmin
= 7.5 MW
Q
Cmin
= 10 MW
Heat
sink
Heat
source
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 31
Utility selection Utility selection Utility selection Utility selection
For 2 levels of steam @ saturated condition & temperature
of 240 & 180C, determine the loads on the 2 stream levels
that maximises the use of lower pressure steam.
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 32
Utility selection Utility selection Utility selection Utility selection
245
235
195
185
145
75
35
25
H = 1.5
H = -6.0
H = 1.0
H = -4.0
H = 14.0
H = -2.0
H = -2.0
Cold utility
Hot utility
7.5 MW
9.5 MW
3.0 MW
4.0 MW
0 MW
14 MW
12.0 MW
10.0 MW
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 33
Utility selection Utility selection Utility selection Utility selection
Instead of using steam, a hot oil circuit is to be used with a
supply temperature of 280C & CP = 2.1 kJ/kg.K. Calculate
the minimum flowrate of hot oil [Ans: 27.5 kg/s].
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 34
Steam generation Steam generation Steam generation Steam generation
How much low pressure steam @ 120C may be generated
by exploring the use of the rejected heat? [Ans: ~4.2 MW].
Copyright@Dominic Foo H82PLD - Plant Design PTA & GCC - 35
Practice makes perf Practice makes perf Practice makes perf Practice makes perfect! ect! ect! ect!