CDB4313/CDB4313Z – HEAT INTEGRATION

DESIGN OF HEAT EXCHANGER

NETWORK

Heat Exchanger Network Design

Stream Splitting
Threshold Problems

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COURSE LEARNING OUTCOMES
At the end of this course, students shall be able to:

1. Perform targeting exercise to determine the minimum utility requirements

and maximum heat recovery possible for a process using composite curve
or problem table algorithm

2. Design heat exchanger network for achieving maximum energy recovery or

minimum total cost using pinch analysis technique

3. Apply pinch analysis software to perform heat integration and heat

exchanger network design that is cost competitive and taking into account
of sustainability factors

4. Analyze the potential for heat and power integration of a process and the
possible implementation options, and to screen the options using cost
effective strategy

5. Perform correct data extraction from process flowsheet for the purpose of
performing pinch analysis
 Significance of the ‘Pinch’
Steam@ 180ºC Heat Sink – only accepts heat
T (ºC) DHH Q
H
“Cooling above
“Heating below pinch”
pinch” • heat from
• Steam is used rejected to CW
for heating • must
of , instead compensate for
of hot stream loss of ∆HH with
• must add additional
CW for steam for
cooling of heating
“Pinch”

CW@ 30ºC
QC DHC
∆H (kW)
Heat Source – only rejects heat
Significance of the ‘Pinch’
Heat Sink = only accepts heat
DHH Q Cross Pinch Heat
H
Transfer - “upsets”
T (ºC)
the heat balance
X-Pinch heat
transfer Implications:
Not enough
process
heat above,
excess heat
below
“Pinch”
Simple Rule:
Exchange only
DHC high Temp with
QC high temp,
DH (kW) low T with low T
Heat Source – only rejects heat
Significance of the ‘Pinch’
Rules for HEN Design

“No Heating QH,min

below the
pinch”
T (ºC)

No heat
transfer

“No Cooling
above the
pinch”
H (kW)
QC,min
HEN DESIGN
 HEN Design
Grid diagram
HOT 1

C HOT 2

COLD 1

COLD 2 H
• Hot streams run right to left
• Cold streams run left to right
• Hot streams on top; cold streams on bottom
• Hot utility = H
• Cold utility = C
• Heat exchanger between streams =
 HEN Design
Showing the Pinch

PINCH

HOT 1

C HOT 2

COLD 1

COLD 2 H
 HEN Design
Accounting for Pinch Implications

"Allowed" "Forbidden"

The implications of the pinch are easily assessed!!

 HEN Design
Rules for HEN design

• No process to process heat transfer across the pinch

• No inappropriate use of utilities
• No exchanger has a temperature difference < ΔTmin
 HEN Design
Pinch design principle
T

1. Start at the Pinch

2. Then move AWAY

PINCH

ΔH
 HEN Design
Above Pinch

TH, pinch TH, in

Tc, pinch Tc, out

CPH ≥ CPC CPH ≤ CPC

T T
PINCH PINCH

∆Tmin ∆Tmin

ΔH ΔH
INFEASIBLE! FEASIBLE
 HEN Design
Below Pinch

TH, out TH, pinch

Tc, in Tc, pinch

CPH ≤ CPC CPH ≥ CPC

T T
PINCH PINCH

∆Tmin ∆Tmin

ΔH ΔH
INFEASIBLE ! FEASIBLE
 HEN Design
Pinch design principle

1. Start at the Pinch

2. Above Pinch: CPH ≤ CPC

3. Below Pinch: CPH ≥ CPC

 HEN Design
Divide at the pinch
CP
PINCH kW • (ºC)-1
60 º 100 º 170 º
3 3

30 º 100 º 150 º
4 1.5

20 º 80 º 135 º
1 2

80 º 140 º
2 4

QHmin = 65 kW QCmin = 105 kW

 HEN Design
Design above the Pinch

Rule: CPH ≤ CPC

PINCH CP
100 º 170 º
3 3

100 º 150 º
4 1.5

80 º 135 º
1 2

80 º 140 º
2 4
 HEN Design
Design below the Pinch

Rule: CPH ≥ CPC

PINCH CP

60 º 100 º
3 3

30 º 100 º
4 1.5

20 º 80 º
1 2
 HEN Design
Sizing the matches

PINCH CP
100 º 170 º
3 3

100 º 150 º
4 1.5

80 º 135 º
1 2
? kW
80 º 140 º
2 4
? kW

Having identified feasible matches,

how big should we make them?
 HEN Design
Tick-off heuristic (above pinch design)
CP QSTREAM
100 º 170 º
3 3 210
100 º 150 º
4 1.5 75

80 º 117.5º 135 º
1 2 110
75 kW
80 º 132.5º 140 º
2 4 240
210 kW
210
𝑇𝑥 = 80 + = 132.5℃
4

Maximise loads to "tick off" streams

 HEN Design
Fill in the rest

CP QSTREAM
100 º 170 º
3 3 210
100 º 150 º
4 1.5 75

80 º 117.5º 135 º
1 H 2 110
75 kW 35 kW

80 º 132.5º 140 º
2 H 4 240
210 kW 30 kW
 HEN Design
Tick-off heuristic (below pinch design)

PINCH CP QSTREAM

60 º 100 º
3 3 120

30 º 100 º
4 1.5 105

20 º 80 º
1 2 120

120 kW
 HEN Design
Fill in the rest

PINCH CP QSTREAM

60 º 100 º
3 3 120

30 º 100 º
C 4 1.5 105
105 kW

20 º 80 º
1 2 120

120 kW
 HEN Design
Completed design

PINCH CP
60 º 100 º 170 º
3 3

30 º 100 º 150 º
C 4 1.5
105 kW

20 º 80 º 117.5º 135 º
1 H 2
120 kW 75 kW 35 kW
80 º 132.5º 140 º
2 H 4
210 kW 30 kW

QHmin = 65 kW QCmin = 105 kW

 HEN Design
Example
CP
PINCH kW • (ºC)-1
40 º 150 º 250 º
3 15

80 º 150 º 200 º
4 25

20 º 140 º 180 º
1 20

140 º 230 º
2 30

QHmin = 750 kW QCmin = 1000 kW

 HEN Design
Example: Above Pinch

CP QSTREAM
150 º 203.3 º 250 º
2 15 1500

150 º 200 º 1250

4 25

140 º 180 º
1 20 800

800 kW
140 º 181.7 º 230 º
3 30 2700
1250 kW
 HEN Design
Example: Above Pinch

CP QSTREAM
150 º 203.3 º 250 º
2 15 1500

150 º 200 º
4 25 1250

140 º 180 º
1 20 800
800 kW

140 º 181.7 º 205 º 230 º

3 H 30 2700
1250 kW 700 kW 750 kW
 HEN Design
Example: Below Pinch

CP QSTREAM
40 º 150 º
2 15 1650

80 º 150 º
4 25 1750

20 º 52.5 º 140 º
1 20 2400
1750 kW
 HEN Design
Example: Below Pinch

CP QSTREAM
40 º 106.7 º 150 º
C 2 15 1650
1000 kW
80 º 150 º
4 25 1750

20 º 52.5 º 140 º
1 20 2400
650 kW 1750 kW
 HEN Design
Example: Below Pinch

This match violates CP rules

CP QSTREAM
40 º 106.7 º 150 º
C 2 15 1650
1000 kW
80 º 150 º
4 25 1750

20 º 52.5 º 140 º
1 20 2400
650 kW 1750 kW

But it is away from the pinch and therefore feasible

(Must check temperature though!)
 HEN Design
Example: Completed design

PINCH
CP

40 º 106.7 º 150 º 203.3 º 250 º

C 2 15
1000 kW
80 º 150 º 200 º
4 25

20 º 52.5 º 140 º 180 º 20

1
650 kW 1750 kW 800 kW
140 º 181.7 º 205 º 230 º
3 H 30
1250 kW 700 kW 750 kW

QHmin = 750 kW QCmin = 1000 kW

 HEN Design
Working Session 4

Stream data table

Heat
Supply Target
Stream No Capacity
Temperature Temperature
and Type Flowrate
(°C) (°C)
(kW/°C)
1 Hot 180 80 20
2 Hot 130 40 40
3 Cold 60 100 80
4 Cold 30 120 36

ΔTmin = 10 ºC

Design a Network for Maximum Energy Recovery

 HEN Design
Working Session 4

CP
STEP 2
40 º 43 º 70 º
C 1 2 40

120 kW
STEP 1

30 º 60 º
4 1 36

1080 kW
 HEN Design
Working Session 4
CP
80 º 180 º
3 1 20

70 ºC 130 º
2 2 40

60 º 90 º 100 º
3 2 H1 80
2400 kW 800 kW
60 º 115.6 º 120 º 36
4 3 H2
2000 kW 160 kW
 HEN Design
Working Session 4

Maximum Energy Recovery Network

CP
80 º 180 º
3 1 20
STEP 2
40 º 43 º 70 º 130 º
C 1 2 2 40
120 kW
STEP 3 STEP 4
STEP 1 STEP 5
60 ºC 90 º 100 º
3 2 H1 80
2400 kW 800 kW
STEP 6
30 º 60 º 115.6 º 120 º 36
4 1 3 H2
1080 kW 2000 kW 160 kW
 HEN Design
Working Session 4
Again Maximum Energy Recovery
CP
80 º 140 º 180 º
3 4 1 20
40 º 43 º 70 º 130 º
C 1 2 2 40
120 kW

60 º 90 º 100 º
3 2 4 80
2400 kW 800 kW
30 º 60 º 93.3 º 120 º 36
4 1 3 H
1080 kW 1200 kW 960 kW
STREAM SPLITTING
 Stream Splitting
Above Pinch

PINCH

CP
o
100 12
1

100o
2 20

100o
3 7

90o T > 90o

4 15

90o T > 90o

5 30

What do we do?
 Stream Splitting
Above Pinch

PINCH CP
100o
1 12
If the number of hot
100o
2 20
stream is greater than
100o 3 7 the number of cold
streams

o
90 15
 split the cold stream
4
o
90
5 30
 Stream Splitting
Above Pinch

Rule:

Above the pinch, NH ≤ NC

• NH = number of hot streams

• NC = number of cold streams
 Stream Splitting
Below Pinch

PINCH
CP
T < 100o 100o
35 1

T < 100o 100o

2
60

3
90o
24

90o
30 4

5
90o
20
 Stream Splitting
Below Pinch

PINCH
If the number of CP
o
100
cold stream is 35 1

greater than a
o
100 2
60

number of hot
streams
 split the hot
stream
90o
24 3

90o
30 4

90o
20 5
 Stream Splitting
Below Pinch

Rule:

Below the pinch, NH ≥ NC

• NH = number of hot streams

• NC = number of cold streams
 Stream Splitting
Example: Below Pinch

CPH ≥ CPC
The N H ≥ NC
rules:
5 7
4
PINCH CP

30° 100°
1 5

40° 100° 4
2

No feasible
15° match! 90° 7
3
 Stream Splitting
Example: Below Pinch

CPH ≥ CPC
NH ≥ NC

5 4
7
4 3

PINCH CP
30° 40° 100°
C1 1 5

40° 43.75° 100° 4

C2 2

Split cold stream 3

90° 4
15°
300 kW 3
3

225 kW
 Stream Splitting
Choosing split ratio

What about ?
CPH ≥ CPC
N H ≥ NC

5 3.5
7
There is an
4 3.5
infinite number
or ? of split ratios !
CPH ≥ CPC
NH ≥ NC

5 4.5
7
4 2.5
 Stream Splitting
Choosing split ratio

Save one unit by ticking off two streams at once.

PINCH CP
65 kW
30o 43o 100o
C 1 5

40o 40o 100o 4

C 2

90o 3.8

15o 285kW 3.2

3

240 kW
𝑄 = 𝐶𝑃 × ∆𝑇
4 100 − 40 = 𝐶𝑃𝐶1 90 − 15
𝐶𝑃𝐶1 = 3.2
 Stream Splitting
Summary

Above Pinch
Stream data
at pinch

Yes Yes
CPH ≤ CPC NH ≤ NC
for Pinch
matches? ?

No
No
Split Cold
Stream

Split Hot
Stream

Place
Matches
 Stream Splitting
Summary

Below Pinch
Stream data
at pinch

Yes Yes
CPH ≥ CPC NH ≥ NC
for Pinch
matches? ?

No
No
Split Hot
Stream

Split Cold
Stream

Place
Matches
 Stream Splitting
Stream data Working Session 5

Supply Target Heat Capacity

Stream Type Temperture Temperture Flow rate
TT (oC) TT (oC) (KW oC-1)
1 Hot 750 350 45
2 Hot 550 250 40
3 Cold 300 900 43

4 Cold 200 550 20

ΔTmin = 50 ºC
DTmin = 50 oC
The pinch
Q =is 9200
at 550kW
ºC / 500 ºC
Hmin
QHmin = 9200 QCmin = 6400
QCmin = 6400 kW
Design a network for maximum energy recovery
Design a network for maximum energy recovery
 Stream Splitting
Working Session 5

Below Above
CPH ≥ CPC CP H≤ CP C
N ≥ NC
H
NH ≤ NC

45 43 45 43
40 20 20

Duties above
PINCH
CP the Pinch
350° 550° 750°
45 1 9000kW
550°
250°
40 2

300° 500° 900°

43 3 17200 kW
200° 500° 550°
20 4 1000 kW
 Stream Splitting
Working Session 5

Above Above

CP H≤ CP C CP
NH ≤ NC
40
45 550o 750o
40 43 5 1
45
5 20
20 x (550 – 500) = CP x (750 – 550)
40 CP = 5

500o 900o
43 3

500o 550o
20
4
 Stream Splitting
Working Session 5

Network Design
CP
CP=40 750o
350o 358.9o 550o
45 C
400
1 CP=5
40 250o 400o 550o 2
C
6000 900o
300 500o
43 3 o H
9200
8600 8000
200o 500o 550o
20 4

6000 1000
THRESHOLD PROBLEMS
 Threshold problems
No integration
T

Steam

Worst case
scenario!

CW

ΔH

When no heat recovery is performed, there is need

for both hot and cold utilities
Threshold problems
Recovering heat
T Steam

ΔTmin

CW

ΔH

ΔTmin = 20ºC ► Process Heat Recovery

 Threshold problems
Reducing ΔTmin: No Hot Utility
T

ΔTmin Reduced

CW

ΔH

ΔTmin = 14ºC ► More Process Heat Recovery

 Threshold problems
Hot End

CW

ΔH
 Threshold problems
Cold End

T
Steam

ΔH
 Threshold problems
How to design the HEN

T ST

ΔH, MW

Treat exactly like a PINCH problem

 HEN Design
Working Session 6

Stream data table

Heat
Supply Target
Stream No Capacity
Temperature Temperature
and Type Flowrate
(°C) (°C)
(kW/°C)
1 Hot 180 80 20
2 Hot 130 40 40
3 Cold 60 100 80
4 Cold 30 120 36

ΔTmin = 7 ºC
The pinch is at 67 ºC / 60 ºC
QHmin = 840 QCmin = 0

Design a Network for Maximum Energy Recovery

 Design Below the Pinch
CPH CPC
2: 40 4: 36 67 ºC CP
37 ºC

40 º 67 º 40
1 2

STEP 1

Q(4) = 1080 kW
Q(2) = 1080 kW
30 º 60 º
4 1 36

1080 kW
30 ºC 60 ºC
 Design Above the Pinch
CPH CPC Matches 67 ºC CP
2: 40 3: 80 2&3
1&4 80 º 180 º
1: 20 4: 36 3 1 20

67 ºC 130 º
Match 2 2 2 40
Q2  130  67  40  2520 kW
STEP 2 STEP 3
Q3   100  60  80  3200 kW
STEP 4
TS3,M2  60 
2520
 91.5 60 º 91.5 º 100 º
80 3 2 H1 80
2520 kW 680 kW
Match 3 STEP 5
60 º 115.6 º 120 º
Q1  180  80  20  2000 kW 4 3 H2 36

Q4  120  60  36  2160 kW 2000 kW 160 kW

TS4,M3  60 
2000 60 ºC
 115.6
36
 Complete Design
Maximum Energy Recovery Network

67 ºC CP
80 º 180 º
3 1 20

40 º 67 º 130 º
1 2 2 40

STEP 3
STEP 2
STEP 1 STEP 4
60 ºC 91.5 º 100 º
3 2 H1 80
2520 kW 680 kW
STEP 5
30 º 60 º 115.6 º 120 º 36
4 1 3 H2
1080 kW 2000 kW 160 kW
60 ºC