4 Heat Integration and Utility

4.1 Introduction
Heat integration is a technique in designing a process to reduce the consumption of energy as
well as to maximize heat recovery. This chapter focuses on the heat integration work done
based on the design of the plant. Heat integration is done using pinch technology which enables
process designers to determine the best arrangement of heat exchange to achieve maximum
heat recovery. Once the pinch is determined, the hot and cold utilities are calculated, and the
heat exchanger network is drafted on the process flow diagram.

4.2 Heat Exchanger Network

Heat exchanger network is the way to design a heat integration work based on the hot and cold
stream. It is important to have best arrangement of heat exchange in order to maximize heat
recovery and to achieve the minimum usage of utilities.

4.2.1 Pinch Technology

Pinch technology is a rigorous and structured approach that can reduce operating costs,
improve energy efficiency and minimize capital investment. Every transfer equipment such as
heat exchanger network requires a larger transfer area and each of the design has a pinch point
whenever the driving forces for mass or heat transfer reaches minimum.

Pinch technology establishes a temperature difference, designated as the pinch point, which
separates the overall operating temperature region observed in the process into two temperature
regions. Once the pinch point is identified, heat from external sources that must be supplied to
the process at temperatures above the pinch whereas heat removed from the process by cooling
media at temperatures below the pinch can all be determined. This analysis approach
maximizes heat recovery in the process with the establishment of a heat exchanger network.
After the analysis, an engineer must decide on the trade-off between the energy recovered and
the capital cost involved in the heat recovery system in order to maximize economic potential.

The objective of pinch technology is to develop a heat exchanger network (HEN) in a plant to
optimize the use of energy, thus minimizing the operating cost. The concepts behind pinch
technology that should be abided when performing pinch design are:
1. Common values of ΔTmin in the industry:
a) Oil refining = 20 – 40°C
b) Petrochemical = 10 – 20°C
c) Chemical = 10 – 20°C
 d) Low temperature processes = 3 – 5°C
2. The minimum heating requirement, ǪHmin and minimum cooling requirement, ǪCmin
and the pinch temperature are determined from the cascade diagram.
3. When performing pinch design, there are two pinches known as above pinch, the
Cp,cold should always be greater than or equivalent to Cp,hot. Do the same vice-versa
for below pinch design. The stream pairing should always start with the biggest Cp
value.
4. Comparison of utility consumption before and after maximum energy recovery (MER)
is done in order to determine the MER efficiency (Towler & Sinnott, 2013)

4.2.2 Process Flow for Pinch Technology

Figure 4.1 depicts the process flow for pinch technology.

Step 1: Hot and cold stream identification

Step 2: Construction of stream table

Step 3: Selection of minimum approach

temperature

Step 4: Shifting of stream data

Step 5: Construction of temperature interval

diagram

Step 6: Construction of cascade diagram

Step 7: Heat exchanger network design based on

pinch
Figure 4.1 Process flow for pinch technology
4.2.2.1 Hot and Cold Stream Identification
In this section, the hot stream and cold stream, which are the stream to be cooled down and
the stream to be heated up respectively, are identified.

4.2.2.2 Construction of Stream Table

After identifying hot and cold streams, the operating conditions of hot and cold streams which
include inlet temperature, outlet temperature and heat duty with respect to each of the
equipment are illustrated in Table 4.1. This step is essential as it acts as a reference and
guidance for the following steps.
 Table 4.1 Stream table for involved equipment

Supply Target Mass Mass Heat

Stream Cp ,
Equipment Temperature, Temperature, Flow In, Enthalpy, Duty,
Type (kW/K)
(oC) (oC) (kg/hr) (kJ/kg) (kW)
E-101 25 135 16811.2 254.23 1187.26 Cold 10.79
E-104 -160 40 1287.63 600.92 216.33 Cold 1.08
E-108 155 200 15523.5 168.68 727 Cold 16.16
E-107 116 50 731.182 194.95 39.596 Hot 0.6
E-102 420 50 38634..28 767.44 8234.61 Hot 22.26
E-103 174 -50 23110.8 295.34 1896.11 Hot 8.46
E-105 116 80 1287.63 231.78 83.44 Hot 2.32
E-106 44 35 553.65 199.87 30.7381 Hot 3.42
E-109 125 35 5517.13 187.77 287.765 Hot 3.2
E-110 267 35 9990.43 597.2 1657.31 Hot 7.14

4.2.2.3 Selection of Minimum Approach Temperature

Minimum approach temperature, ΔTmin represents the smallest temperature difference that
two streams leaving or entering a heat exchanger can have. Typical values are ranged from
10°C to 20°C for petrochemical industry. Therefore, the value of 20°C is chosen for this plant.

4.2.2.4 Shifting of Stream Data

This step involves the calculation of new temperature by using ΔTmin obtained in the previous
step. The formula used are shown in Equation 4.1, Equation 4.2 and Equation 4.3.
1
𝑇ℎ𝑜𝑡 𝑠𝑡𝑟𝑒𝑎𝑚 = 𝑇 − 2 ∆𝑇𝑚𝑖𝑛 Eq. 4.1
1
𝑇𝑐𝑜𝑙𝑑 𝑠𝑡𝑟𝑒𝑎𝑚 = 𝑇 + 2 ∆𝑇𝑚𝑖𝑛 Eq. 4.2
𝐻𝑒𝑎𝑡 𝑑𝑢𝑡𝑦
𝐶𝑝 = Eq. 4.3
𝑇𝑖𝑛 −𝑇𝑜𝑢𝑡

This step is essential as it provides the data required for the following step which is to construct
the temperature interval diagram. The table below shows the data acquired from the shifting of
stream table.
Table 4.2 Shifted stream table

Supply Target Mass Mass Heat

Stream Cp ,
Equipment Temperature, Temperature, Flow In, Enthalpy, Duty,
Type (kW/K)
(oC) (oC) (kg/hr) (kJ/kg) (kW)
E-101 35 145 16811.2 254.23 1187.26 Cold 10.79
E-104 -150 50 1287.63 600.92 216.33 Cold 1.08
E-106 54 45 553.65 199.87 30.7381 Cold 2.69
 E-107 126 60 731.182 194.95 39.596 Cold 0.6
E-108 165 210 15523.5 168.68 727 Cold 16.16
E-109 135 45 5517.13 187.77 287.765 Cold 3.2
E-110 277 45 9990.43 597.2 1657.31 Cold 7.14

E-102 410 40 38634..28 767.44 8234.61 Hot 22.26

E-103 164 -60 23110.8 295.34 1896.11 Hot 8.46

E-105 277 45 1287.63 231.78 83.44 Hot 2.32

4.2.2.5 Construction of Temperature Interval Diagram

In this step, all streams are presented by a vertical line, where cold stream (represented by blue
line) and hot stream (represented by red line) are placed in the grid diagram. The cold and heat
duty for each temperature interval as shown in Table 4.3 is calculated. The difference in cold
and hot duty is then calculated and the result is represented as deficit for positive value and
surplus for negative value. This step is essential as the difference in heat duty obtained will be
used to construct the cascade diagram in the following step.
 Table 4.3 Temperature interval table

COLD HOT
Temperature
(celcius) E-101 E-104 E-107 E-106 E-107 E-109 E-110 E-102 E-103 E-105 COLD HOT COLD - HOT SURPLUS/DEFICIT
410 22.26
0 2960.01 -2960.008459
277 7.14
0 1969.51 -1969.512081 SURPLUS
210
727 1322.81 -595.8066216 SURPLUS
165 16.16
0 29.3957 -29.3957027 SURPLUS
164 8.46
0 530.047 -530.0467128 SURPLUS
150
0 189.302 -189.3023974 SURPLUS
145
107.933 378.605 -270.6720676 SURPLUS
135 3.2
97.1395 369.544 -272.4048609 SURPLUS
126 0.6
215.865 833.21 -617.3441352 SURPLUS
106 2.32
388.558 1583.22 -1194.659443 SURPLUS
70
107.933 439.783 -331.8498454 SURPLUS
60
64.7596 260.27 -195.5099072 SURPLUS
54 2.69
43.1731 175.002 -131.828827 SURPLUS
50
59.3746 218.752 -159.3777838 SURPLUS
45
59.3746 153.602 -94.22778381 SURPLUS
40
59.3746 42.3239 17.05072971 DEFICIT
35 10.79
102.757 804.154 -701.3970446 SURPLUS
-60
97.3485 0 97.3485 DEFICIT
4.2.2.6 Construction of Cascade Diagram
The cascade diagram is illustrated in Figure 4.3. The net amount of energy in each temperature
interval is presented in the previous step. If there is excess energy in a given temperature
interval, this energy can be cascaded down to the next temperature level. The heat flow showed
in this cascade diagram has to be positive throughout the course, if negative value is present
along the cascade diagram, normalization is required to convert the negative flow to positive
flow.
Temperature COLD - HOT (kW) Normalize (kW)
(oC)
410 0
-2960.008459
277 2960.008459
-1969.512081
210 4929.520541
-595.8066216
165 5525.327162
-29.3957027
164 5554.722865
-530.0467128
150 6084.769578
-189.3023974
145 6274.071975
-270.6720676
135 6544.744043
-272.4048609
126 6817.148904
-617.3441352
106 7434.493039
-1194.659443
70 8629.152482
-331.8498454
60 8961.002328
 -195.5099072
54 9156.512235
-131.828827
50 9288.341062
-159.3777838
45 9447.718846
-94.22778381
40 9541.94663
17.05072971
35 9524.8959
-701.3970446
-60 10226.29294
97.3485
-150 10128.94444

Figure 4.3 Cascade diagram

From the cascade diagram, it is shown that the lowest value at 410°C with -2960.0085kW. The
feasible design has a pinch temperature at 410°C.

4.2.2.7 Heat Exchanger Network Design Based on Pinch

In this step, the heat integration between the heat duties of each equipment takes place and a
new heat exchanger network can be achieved. This heat integration is done based on the pinch
temperature, 340°C, which is obtained from the previous step. The hot and cold pinch
temperatures are calculated using the formula below:

1
𝑇ℎ𝑜𝑡 𝑝𝑖𝑛𝑐ℎ = 𝑃𝑖𝑛𝑐ℎ 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 + ∆𝑇𝑚𝑖𝑛 Eq. 4.4
2
1
𝑇𝑐𝑜𝑙𝑑 𝑝𝑖𝑛𝑐ℎ = 𝑃𝑖𝑛𝑐ℎ 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 − ∆𝑇𝑚𝑖𝑛 Eq. 4.5
2

∴ 𝑇ℎ𝑜𝑡 𝑝𝑖𝑛𝑐ℎ = 420°𝐶; 𝑇𝑐𝑜𝑙𝑑 𝑝𝑖𝑛𝑐ℎ = 400°𝐶

Heat integration falls under two categories, which is below pinch temperature where integration
occurs only at temperature which is below the pinch temperature, and above pinch temperature
where integration only occurs at temperature which is above the pinch temperature. No
integration between temperature at below pinch and above pinch is permitted. Besides, in order
to perform heat integration correctly, a few pinch analysis criteria have to be obeyed. The
criteria include:
1. For below the pinch, heat capacity of hot stream (CpH) ≥ heat capacity of cold stream
(CpC).
2. For above the pinch, CpH ≤ CpC.
3. Integration between above pinch and below pinch temperature is not allowed.
4. If Cp value is too large for either of the streams, consider splitting the stream.
5. Find arrangement that meets maximum heat recovery as shown in cascade diagram.
6. The remaining heat duty is to be covered by using heater or cooler.

Figure 4.5 illustrates the heat integration performed on heat exchanger network of Liquid
Fuel production plant which obeys the stated rules of thumb.
HEAT DUTY,kW EQUIPMENT PINCH POINT Cp, kW/k
30.3781
30.3781 E-106 45 C 54 420 3.42
39.596
39.596 E-107 60 C 126 420 0.6
287.765
287.765 E-109 45 C 135 420 3.2
1657.31
1657.31 E-110 45 C 277 420 7.14
6320.35 kW
8234.61 E-102 50 C 420 22.2557
1679.78 kW
1896.11 E-103 -50 C 174 420 8.464777
83.44
83.44 E-105 80 C 116 420 2.317778

1187.26 E-101 25 135 400 10.79327

216.33 E-104 -160 40 400 1.08165

727 E-108 155 200 400 16.15556

4.2.2.8 Maximum Energy Recovery (MER)

After the heat integration using pinch technology, the maximum energy recovery (MER) and
total hot and cold utilities are determined. In order to calculate the percentage of energy saving,
the formula below is employed.
[𝐻𝑒𝑎𝑡 𝑑𝑢𝑡𝑦 (𝐵𝑒𝑓𝑜𝑟𝑒 𝐻𝐸𝑁)−𝐻𝑒𝑎𝑡 𝑑𝑢𝑡𝑦 (𝐴𝑓𝑡𝑒𝑟 𝐻𝐸𝑁)
𝐸𝑒𝑛𝑒𝑟𝑔𝑦 𝑆𝑎𝑣𝑖𝑛𝑔 = Eq. 4.6
𝐻𝑒𝑎𝑡 𝑑𝑢𝑡𝑦 (𝐵𝑒𝑓𝑜𝑟𝑒 𝐻𝐸𝑁)
 Table 4.4 and 4.5 show the summary of heat equipment duties before and after heat
exchanger network (HEN) and comparison of energy requirement respectively.

Table 4.4 Summary of heat equipment duties before and after HEN

Equipment Before HEN, kW After HEN, kW

Heating duty Cooling duty Heating duty Cooling duty
Heater
E-101 1187.26 - 0 -
E-104 216.33 - 0 -
E-108 727 - 0 -
Cooler
E-102 - 8234.61 - 6320.35
E-103 - 1896.11 - 1763.22
E-105 - 83.44 - 83.44
E-106 - 30.378 - 30.378
E-107 - 39.596 - 39.596
E-109 - 287.765 - 287.765
E-110 - 1657.31 - 1657.31
Total 2130.59 12229.209 0 10182.059

Table 4.5 Comparison of energy requirement

Energy Before HEN, kW After HEN, kW Saving (%)

Hot utility 2130.59 0 100.00
Cold utility 12229.209 10182.059 16.74
Total consumption 14359.799 10182.059 29.09

Table 4.5 shows that 100.00% and 16.74% of energy are saved from hot and cold utilities
respectively.

All sizing affected by the newly proposed HEN were revised and re-updated for all
equipment. The latest process flow diagram after heat exchanger network analysis has been
done can give a better heat recovery, and will minimum consumption and cost of hot and cold
utilities.