31/07/2012

Lecture Content

The grid diagram for HEN design
CHE 4173 Sustainable Processing II
The pinch design method (PDM)
Heat Exchanger Network – Grid Diagram & PDM – CP table
– “Tick-off “ heuristic

Minimum HE unit targeting

Stream splitting

Network evolution

Dr. Irene Chew

Sunway Campus

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Heuristics for HEN design The composite curves QHmin

Cost ∆Tmin
=20 ͦC
T (ºC)
Total

Energy Pinch
Heat sink
Capital
Heat
∆Tmin source

No individual heat exchanger should have a temp difference ∆Tmin
< than ∆Tmin

To achieve energy targets, must not transfer heat across the
pinch by:
H (MW)
– Process-process heat transfer QCmin

– Inappropriate use of utility

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Heat transfer across pinch

Q +XP Hmin
Don’t cold above the pinch
Q +XP Hmin
T (ºC) T (ºC)

Heat sink Heat sink

XP

Heat Heat
source source XP

QCmin+XP
H (MW) QCmin
H (MW)

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Don’t heat below the pinch

Q Hmin
T (ºC)

XP Heat sink
Let’s design together
while we go along …
Heat
source

QCmin+XP
H (MW)

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Back to the previous example The grid diagram

Feed 2 230ºC 200ºC Product 2
140ºC
Reactor 2 80ºC
To comply with the rules, process should be divided at the
Feed 1 180ºC
250ºC pinch
Reactor 1 Off gas, 40ºC
20ºC
The grid diagram:
40ºC Pinch CP ∆H
Below pinch Above pinch
(MW/ºC) (MW)
Product 1, 40ºC 40 150 250
2 0.15 31.5
Target
DH Heat capacity 80 150 200
Supply temp, 4
0.25 30.0
Steam Type temp, flowrate, CP
TS (ºC) (MW) (MW.K-1)
TT (ºC) 20 140 180
1. Reactor 1 feed Cold 20 180 32.0 0.20 1
0.20 32.0
2. Reactor 1 product Hot 250 40 –31.5 0.15 3
140 230
3. Reactor 2 feed Cold 140 230 27.0 0.30
0.30 27.0
4. Reactor 2 product Hot 200 80 –30.0 0.25
QC, min = 10 MW QH, min = 7.5 MW
Note: Heat capacity flowrate, CP = m.Cp
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Region above pinch Region below pinch

Pinch CP ∆H Pinch CP ∆H
40 150
150 250 2 0.15 16.5
2 0.15 15.0
80 150
150 200 4 0.25 17.5
4 0.25 12.5

140 180 0.20 8.0 20 140

1 1 0.20 24.0

3 140 230 0.30 27.0

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The pinch design method (PDM) CP inequality

1. Start design at the pinch T (ºC)
– Pinch is the most constrained region of the network Above pinch:
– At the pinch, ∆Tmin exists between all hot & cold streams 
number of feasible matches is limited CPH ≤ CPC
Pinch
– Start design at the pinch avoid trouble in stream matching at
later stage
2. The CP inequality for individual match
∆Tmin
– Above pinch: CPH ≤ CPC
– Below pinch: CPH ≥ CPC
Below pinch:
3. The CP table
4. The “tick-off” heuristic
CPH ≥ CPC
H (MW)

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CP inequality Pinch The CP table

Below pinch Above pinch Below pinch Above pinch
40 150 250
2
CPH ≥ CPC CP’s in CPH ≤ CPC
80 150 200
4
0.25 0.2 descending 0.25 0.3
1
20 140 180 0.15 order 0.15 0.2
140 230
3
Pinch CP Pinch CP
Below pinch: Above pinch:
CPH ≥ CPC CPH ≤ CPC 40 150
2
150 250
2
0.15 0.15
80 150 150 200
4 4
Generalisation: CPout ≥ CPin 0.25 0.25

Note:
– Only apply at the pinch & when both end of the match are at 20 140 140 180
1 1
pinch conditions 0.20 0.20
140 230
– Away from the pinch, temp differences increase  no longer 3 0.30
essential to obey CP inequalities

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The “tick-off” heuristic Region above the pinch CP ∆H

Pinch

Minimum number of heat exchanger units leads to reduced capital cost 7
 achieved by “tick-off” heuristic 150 203.3 250
√ 2 0.15 15.0

Individual units are made as large as possible, i.e. smaller of the 2
heat duties on the matched stream 150 200

Tick-off the stream where heat is fully recovered √ 4 0.25 12.5

Proceed to other streams away from pinch

Complete the design with hot & cold utility:
– Only use hot utility above the pinch 1 140 √ 180
0.20 8.0
– Only use cold utility below the pinch 8.0 7.5
14.5
3 140 √ 181.7 205 H 230 0.30 27.0
12.5 7.0 7.5

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Region below the pinch Pinch CP ∆H A complete network

Pinch
10 40 C 150 250 2
40 106.7 150
C √ 2 0.15 16.5
10.0
10.0 80 150 200
80 150 4
√ 4 0.25 17.5

6.5 1 20 140 180

20 52.5 140
1 √ 0.20 24.0
6.5 17.5 8.0
3 140
17.5
H 230
6.5
Utility targets matched (refer to
CC & PTA for this problem in
earlier lecture) 12.5 7.0 7.5
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Some remarks on PDM Number of heat exchange units

Minimum number of heat exchanger in a HEN:

Tick-off heuristic occasionally may cause problem, be
aware Nunits = S – 1

Minimum number of heat exchanger units: where S = number of streams including utilities
– The tick-off heuristic of PDM steers the network design towards
Due to the existence of the pinch point, unit targets is
the minimum number of heat exchanger units
applied to both sides of the pinch:
– The stream that has been ticked-off is no longer part of the
remaining design problem  ensures that a stream is removed Nunits = [SAbove pinch – 1] + [SBelow pinch – 1]
from the problem once a unit is placed. Pinch

The grid diagram: Below pinch Above pinch

General steps of PDM: Steam
– Divide the region at the pinch (i.e. above/below pinch) 1
– Start design at the pinch, moving away.
2
– At the pinch, temp feasibility requires that CPout ≥ CPin Nunits = (5 – 1) + (4 – 1) = 7
3
– Loads of heat exchangers are determine by using tick-off 4
heuristic. CW
– Away from pinch, design is more flexible  consider other
practical factors, e.g. operability, plant layout,HENetc.
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The highway analogy Do we have min # of HX?

Nunits = (4 – 1) + (5 – 1) = 7
Kajang KL
Kajang KL 40 C 150 250 2
Semenyih 10.0
80 150 200 4
KLIA Semenyih Putrajaya

1 20 140 180
Kajang KL What is the
minimum no of road 6.5 17.5 8.0
needed to connect all 3 140 H 230
Semenyih Putrajaya cities? 12.5 7.0 7.5
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Working session Min # of HX units

Supply temp, Target temp, Heat capacity
∆H Nunits = _____ + _____ = ____
Steam Type flowrate, CP
TS (ºC) TT (ºC) (MW)
(MW.K-1) 60 400 1
1. Hot 400 60 0.3
2. Hot 210 40 0.5
3. Cold 20 160 0.4
4. Cold 100 300 0.6 40 210 2

Design a HEN for maximum recovery that feature the minimum number
of units.

Targeting from PTA:
– QH,min = 15 MW 3 20 160
– QC,min = 26 MW

∆Tmin = 20ºC: 300
4 100
– Hot pinch temp = 120ºC
– Cold pinch temp = 100ºC
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Region above the pinch CPH ≤ CPC Region below the pinch
CP’s in
CP ∆H Pinch CP ∆H
Pinch descending 0.5 0.6
order 0.3 0.4
60 60 120
120 200 400 1 0.3
C √ 1 0.3 18
√ 84
18 8
40 C 56 120 2 0.5
120 210 2 0.5 √ 40
√ 45
8

3 100 √ 160
0.4 24 100
3 20 √ 0.4 32
24 15
75 CPH ≥ CPC CP’s in 32
4 100 √ 175 275 H 300 0.6 120 0.5 0.4 descending
0.3
45 60 15 order
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Complete network Stream splitting

The PDM allows for minimum utility (or maximum energy recovery)
60 400 1
using minimum number of units.

Stream splitting needs to be considered in the following situations:
– Number of streams at the pinch
40 210 2 – CP inequality cannot be met at the pinch

3 20 160

4 100 300

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Number of streams above pinch Number of streams below pinch

Pinch Pinch Pinch Pinch
100 100 T < 100 100 T < 100 100
1 1 1 1
100 100 T < 100 100 T < 100 100
2 2 2 2
100 100
? 3 3
90 90
3 3
90 T > 90 90 90 90
4 4 4 4
90 T > 90 90 90 90
5 5 5 ? 5

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CP inequality above pinch CP inequality below pinch

Above pinch Above pinch Below pinch Below pinch
CPH ≤ CPC CPH ≤ CPC CPH ≥ CPC CPH ≥ CPC
SH ≤ SC SH ≤ SC SH ≥ SC SH ≥ SC
4 3 4 5 5 4
5 5 7 7
3 2 3 4 4 3
Pinch CP Pinch CP Pinch CP Pinch CP
100 100 100 100
1 5 1 3 1 5 1 5
100 100
2 4 2 4
2

4
90 90 90
2 2 3 3
4 4 7 90 3
90 90
3 3 3 3 Remark: New CP values may vary, so long as CP inequalities are satisfied.
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Stream splitting algorithms Stream data Working session

Supply temp, Target temp, Heat capacity
at pinch Steam Type flowrate, CP
∆H
TS (ºC) TT (ºC) (MW.K-1) (MW)

CPout ≥ CPin 1. Hot 720 320 0.045

Yes Yes
for pinch Nout ≥ Nin? 2. Hot 520 220 0.040
3. Cold 300 900 0.043
matches?
4. Cold 200 550 0.02
No

Design a HEN for maximum recovery that feature the minimum number
Split “out” of units.
No stream
Targeting from PTA:
– QH,min = 9.2 MW
Split “in” – QC,min = 6.4 MW
stream

∆Tmin = 20ºC:
Place – Hot pinch temp = 520ºC
matches – Cold pinch temp = 500ºC

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Region above the pinch Region below the pinch

Pinch CP ∆H Pinch CP ∆H
0.4
520 720 1 0.040 320 C 328.9 520 1 0.045 9
√ 0.045 89 √
0.4
√ 0.005 1 220 370 520
6
C √ 2 0.040 12
6
9.2
3 500 √ 686 H 900
0.043 17.2 3 300 √ 500 0.043 8.6
8.0 9.2 8.6
4 500 √ 550
0.020 1 4 200 √
500
0.020 6
1.0 6.0
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Complete network
Nunits = _____ + _____ = ____

320 720 1
Practice makes
220 520 2
perfect!
3 300 900

4 200 550

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Network optimisation Heat loops Pinch is

ignored

None of the heat exchangers in a HEN synthesised by PDM should
have a temp difference < ∆Tmin. –U +U
40 250

Once a HEN is synthesised, it can undergo continuous optimisation, C 2
the constraints of no heat exchangers having temp difference < ∆Tmin
can be relaxed (pinch is ignored). 80 200
4

Heat exchanger duties will be redistributed:

– Some become bigger 20 180
1
– Some become smaller or removed (new duty = 0) –U +U
230

Useful tools: Heat loop 3 H

– Utility paths – lines that connects between 2 utilities

– Heat loops – path that begins & ends at the same point

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Heat loops Utility paths

Utility path
+V –V +W –W
40 250 40 250
C 2 C 2
–V +V
80 200 80 200
4 4

20 180 20 180
1 1
–V +V
230 230
3 H 3 H

+V –V –W +W

Heat loop

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Utility paths Some remarks

For heat exchanger with new heat duty = 0, the exchanger
+X –X +X –X
is removed from the network
40
C
250
2
During optimisation, design is no longer constrained to
have temp difference > ∆Tmin (very small ∆Tmin should be
avoided for practical reasons)
80 200
4

Pinch no longer divides design in independent
thermodynamic regions (above & below pinch)  main
concern is to reduce cost
20 180
1
Heat loops, utility paths & stream splits offer degree of
–X +X
freedom for manipulating network cost
230
To optimise network:
3 H
Utility path
–X +X – At fixed energy consumption: loops & stream splits
– Varying energy consumption is allowed: include utility paths

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Working session

Evolve the HEN designed earlier by PDM to simplify its structure:

– Remove smallest unit from the network by exploiting degree of

freedom in a loop
Practice makes
– Recalculate the network temp & identify any violations of ∆Tmin
= 10ºC constraint
perfect!
– Restore the original ∆Tmin = 10ºC throughout the network by
exploiting a utility path

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Heat loops 6.5

Identify ∆Tmin violations
CP ∆H ∆Tmin CP ∆H
violations
(MW/ºC)(MW) (MW/ºC)(MW)
40 250 40 106.5 250
C 2 0.15 31.5 C 2 0.15 31.5

10.0 10.0
80 200 80 200
4 0.25 30.0 4 0.25 30.0

20 180 20 107.5 180

1 0.20 32.0 1 0.20 32.0
6.5 17.5 8.0 6.5 17.5 14.5
230 230
Heat loop 3 H 0.30 27.0 3 H 0.30 27.0
12.5 7.0 7.5 12.5 7.0 7.5

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Utility path Final network (less 1 unit)

Restore ∆Tmin = CP ∆H CP ∆H
10ºC
(MW/ºC)(MW) (MW/ºC)(MW)
40 117.5 250 40 117.5 250
C 2 0.15 31.5 C 2 0.15 31.5
10.0 + x 11.6
80 200 80 200
4 0.25 30.0 4 0.25 30.0

20 107.5 180 20 107.5 180

1 0.20 32.0 1 0.20 32.0
17.5 14.5 17.5 14.5
230 230
3 H 0.30 27.0 3 H 0.30 27.0
12.5 7.0 – x 7.5 + x 12.5 5.4 9.1

Answer: x = 1.6 MW Answer: x = 1.6 MW

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