Process Systems Engineering-Chapter 3-Introduction To Process Integration

CBEg 6152-Process Systems Engineering (PSE)
Introduction to Process Integration
By
Dr. Eng. Shegaw Ahmed
School of Chemical & Bio Engineering
Addis Ababa Institute of Technology
Addis Ababa University
March, 2018
1
SCHOOL OF CHEMICAL AND BIO ENGINEERING
ADDIS ABABA INSTITUTE OF TECHNOLOGY(AAiT)
ADDIS ABABA UNIVERSITY (AAU)
CBEg 6152-PSE-Outline
CHAPTER-1-Introduction to Process
CHAPTER-3-Introduction to Process Integration
Systems Engineering
• Synthesis of Heat Exchange Networks
• Definitions of Process Systems Engineering
• Synthesis of Mass Exchange Networks
• The Concept of Systems Engineering
• The Paradigms of Process Systems
Engineering CHAPTER-4-Optimization of Process Systems
• Application of Optimization Techniques for

CHAPTER-2-Process Modelling and Simulation Design and Operation
• Mathematical Modelling Techniques of • Multivariable Search Techniques
Chemical Processes • Linear Programming (LP)
• Conceptual Process Synthesis and Analysis • Nonlinear Programming (NLP)
• Fundamental of Process Control Systems • Dynamic Programming
• Process Engineering Fundamentals • Integer (IP) and Mixed Integer Programming
• Steady State and Dynamic Simulation (MIP)
• Distribution and Critical Path Networks
Chapter 3. …Process Integration
• Process Industries are among the most important manufacturing facilities.
• They span a wide range of industries including
o chemical, petroleum, gas, petrochemical, pharmaceutical, food,

microelectronics, metal, textile, and forestry products . . .
• The performance of these industries is strongly dependent on their

engineering and engineers
• So, what are the primary responsibilities of process engineers in the

process industries?
• Many process engineers would indicate that their role in the process
industries is to design and operate industrial processes and make them
work faster, better, cheaper, safer, and greener
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• All of these tasks lead to more competitive processes with desirable profit margins
and market share.
• Specifically, these responsibilities may be expressed through the following specific

objectives:
1. Process innovation 2. Profitability enhancement
3. Yield improvement 4. Capital-productivity increase
5. Quality control, assurance, and enhancement
6. Resource conservation 7. Pollution prevention
8. Safety 9. Debottlenecking
• These objectives are also closely related to the key drivers for Process Engineering
Research, Development, and Changes in the primary chemical process industries
4
The key drivers for Process Engineering research, development, and changes in
the primary chemical process industries. These themes are:
o Reduction in raw material cost
o Reduction in capital investment
o Reduction in energy use
o Increase in process flexibility and reduction in inventory
o Ever greater emphasis on process safety
o Increased attention to quality
o Better environmental performance
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Process Integration refers to the system oriented thermodynamics-based, integrated

approaches to the analysis, synthesis and retrofit of process plants. The goals of process
integration are
• to integrate the use of materials and energy, and
• to minimize the generation of emissions and waste
Process Integration is built on three basic concepts

o Consider the big picture first by looking at the whole manufacturing process as an
integrated system of interconnected
o Apply process-engineering principles, such as thermodynamics, the attainable
performance targets on the use of materials and minimum utility consumptions, the
minimum CO2 and NOx
o emission levels, the minimum freshwater requirement, etc.).
o Finalize the details of process design and retrofit later to realize the established
performance targets
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Chapter 3. …Process Integration Techniques
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Chapter 3. …Heat Exchanger Networks
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• Most industrial processes involve transfer of heat either from one process
stream to another process stream (interchanging) or from an utility
stream to process stream.
• What is industry challenged about energy consumption and recovery?
• In the present energy crisis scenario all over the world, the target of any
industrial process designer is to maximizes the process-to process heat
recovery and to minimize the utility (energy) requirements.
• To meet the goal of maximize energy recovery or minimum energy

requirement (MER) an appropriate heat exchanger network (HEN) is
required.
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• The basic optimal heat exchanger network (HEN) synthesis

problem can be stated as follows:
o Design a network of Heat Exchangers using available hot and
cold utility if necessary capable of changing the temperatures of
various hot and cold process streams to desired levels with the
minimum capital and operating costs.
• While the capital costs are mainly determined by the total

number of heat exchangers and the net exchanger area, the
operating costs depend on a variety of factors, chief among
them being the utility consumption
10
Composite Curves
• The analysis of the heat exchanger network first identifies sources of heat
(termed hot streams) and sinks (termed cold streams) from
• Consider the problem of two hot stream and two cold streams: just two hot
streams (heat sources) and two cold streams (heat sinks). The initial
temperature (termed supply temperature), final temperature (termed target
temperature) and enthalpy change of both streams.
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First law analysis (Conservation of Energy)
Qi = Fi Cpi ∆Ti
o Therefore, 10 × 103 BTU/hr must be supplied from utilities (if there are no
restrictions on temperature driving force)
Second Law Analysis
• How can we check driving force restrictions?

• Second Law Analysis(You can not transfer heat from a lower temperature to
a higher temperature)
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Chapter 3. …Basic Concepts in Process heat integration
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Identification of the hot, cold and utility streams in the process.
Utility streams: are used to heat or cool process stream, when heat exchange between
process stream is not practical or economic. A number of different hot utilities (steam, hot
water, flue gas, etc) and cold utilities (cooling water, air, refrigerant, etc.) are used in
industry.
27
Thermal data extraction for process and utility stream.
For each hot, cold and utility stream identified, the following thermal data is
extracted for the process material and heat balance flow sheet:
Typical Stream Data
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Selection of Initial ΔTMIN value.

o The design of any heat transfer equipment must always adhere to the second law
of thermodynamics that prohibits any temperature crossover between the hot and
the cold stream i.e. a minimum heat transfer driving force must always be
allowed for a feasible heat transfer design.
o Thus the temperature of the hot and cold stream at the any point in the exchanger
must always have a minimum temperature difference (ΔTMIN). This ΔTMIN
value represents the bottleneck in the heat recovery.
o In mathematical terms, at any point in the exchanger
o The value of ΔTMIN is determined by the overall heat transfer coefficient (U) and
the geometry of the exchanger. In a network design, the type of heat exchanger to be
used at the pinch will determine the practical ΔTMIN for the network.
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A few values of based Linnhoff March’s application experience are tabulated below
for shell and tube heat exchangers.
Typical ΔTmin values.
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Composite Curves
Composite Curves consist of temperature (T) - Enthalpy (H) profiles of heat

availability in the process (the Hot Composite Curve) and heat demands in the
process (the Cold Composite Curve) together in a graphical representation. In
general any stream with a constant heat capacity (CP) value is represented on a
diagram by a straight line running from stream supply temperature to stream target
temperature. When there are a number of hot and cold composite curves simply
involves the addition of the enthalpy changes of the stream in the respective
temperature intervals.
Temperature - Enthalpy relation used

to construct Composite Curves.
A complete hot or cold composite
curves consists of a series of connected
straight lines, each change in slope
represents a change in overall hot
stream heat capacity flow rate (CP).
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Energy targets and “the pinch” with Composite Curves.

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Chapter 3. …Simple-two stream problem
Two-stream exchanger problem
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Chapter 3. …Four stream problem
Hot stream temperature v. enthalpy (a) Separate hot streams

Hot and cold stream composite curves
(b) Composite hot streams
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Chapter 3. …The Problem Table Method
The problem table is the name given by Linnhoff and flower to a

numerical method for determining the pinch temperatures and the
minimum utility requirements; Linnhoff and Flower (1978)
Once understood, it is the preferred method, avoiding the need to
draw the composite curves., for example, tracing paper or cut-outs,
to give the chosen minimum temperature difference on the diagram
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Chapter 3. …The Problem Table Method-The procedure
1. Convert the actual stream temperatures Tact into interval temperatures

Tint by subtracting half the minimum temperature difference from the hot
stream temperatures, and by adding half to the cold stream temperatures:
Interval temperatures for ∆Tmin =10°C
38
2. Note any duplicated interval temperatures. These are bracketed in the Table
3. Rank the interval temperatures in order of magnitude, showing the
duplicated temperatures only once in the order; see the Table .
4. Carry out a heat balance for the streams falling within each temperature
interval:
For the nth interval:
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5. “Cascade” the heat surplus from one interval to the next down the column
interval temperature; figure a below
Cascading the heat from one interval to the next implies the temperature
difference is such that the haet can be transferred between the hot and cold
stream.
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Chapter 3. …The Problem Table Method-Summary
For maximum heat recovery and minimum use of

utilities:
1. Do not transfer heat across the pinch
2. Do not use hot utilities below the pinch
3. Do not use cold utilities above the pinch
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Chapter 3. …The heat Exchange network
Grid representation
o It is convenient to represent a heat exchanger network as a
grid; see Figure below
o The graphical method of representing flow streams and heat
recovery matches is called “Grid Diagram”.
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Chapter 3. …The heat Exchange network-Network design for
maximum energy recovery
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Chapter 3. …The heat Exchange network-The network design above
the pinch
Example problem hot end

design. Infeasible
Example problem hot end

design. Acceptable
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Chapter 3. …The heat Exchange network-The network design above
the pinch
1. Applying this condition at the pinch, stream 1 can be matched

with stream 4, but not with 3.
2. Stream 2 can be matched with stream 3, whilst satisfying the
heat capacity restriction.
46
Chapter 3. …The heat Exchange network-The network design below
the pinch
Example problem cold design. 2/1 Match acceptable, 2/4

match infeasible.
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Chapter 3. …The heat Exchange network-The network design below
the pinch
Stream 4 is at the pinch temperature Ts = 80 0C
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Chapter 3. …The heat Exchange network-Summary
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Chapter 3. …The heat Exchange network-Summarizing
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Chapter 3. …The Problem Table Method-
Example
Determine the pinch temperatures and the minimum utility requirements
for the streams set out in the Table below, for a minimum temperature
difference between the streams of 20 0C. Devise a heat exchanger
network to achieve the maximum energy recovery.
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Solution:
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Solution:
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Chapter 3. …Mass Exchanger Networks—Reading Assignment
54

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CBEg 6152-Process Systems Engineering (PSE)

Introduction to Process Integration

• Application of Optimization Techniques for

• Process Industries are among the most important manufacturing facilities.

• They span a wide range of industries including

o chemical, petroleum, gas, petrochemical, pharmaceutical, food,

• The performance of these industries is strongly dependent on their

• So, what are the primary responsibilities of process engineers in the

• Specifically, these responsibilities may be expressed through the following specific

1. Process innovation 2. Profitability enhancement

3. Yield improvement 4. Capital-productivity increase

5. Quality control, assurance, and enhancement

6. Resource conservation 7. Pollution prevention

o Reduction in raw material cost

o Reduction in capital investment

o Reduction in energy use

o Increase in process flexibility and reduction in inventory

o Ever greater emphasis on process safety

o Increased attention to quality

o Better environmental performance

Process Integration refers to the system oriented thermodynamics-based, integrated

Process Integration is built on three basic concepts

• What is industry challenged about energy consumption and recovery?

• To meet the goal of maximize energy recovery or minimum energy

• The basic optimal heat exchanger network (HEN) synthesis

• While the capital costs are mainly determined by the total

First law analysis (Conservation of Energy)

Second Law Analysis

• How can we check driving force restrictions?

Identification of the hot, cold and utility streams in the process.

Thermal data extraction for process and utility stream.

Typical Stream Data

Selection of Initial ΔTMIN value.

Typical ΔTmin values.

Composite Curves consist of temperature (T) - Enthalpy (H) profiles of heat

Temperature - Enthalpy relation used

Energy targets and “the pinch” with Composite Curves.

Two-stream exchanger problem

Hot stream temperature v. enthalpy (a) Separate hot streams

The problem table is the name given by Linnhoff and flower to a

1. Convert the actual stream temperatures Tact into interval temperatures

Interval temperatures for ∆Tmin =10°C

For the nth interval:

For maximum heat recovery and minimum use of

Example problem hot end

Example problem hot end

1. Applying this condition at the pinch, stream 1 can be matched

Example problem cold design. 2/1 Match acceptable, 2/4

Stream 4 is at the pinch temperature Ts = 80 0C

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