Extractive Distillation

Do Example 1.1 as vapor load calculations …!!!

 Preliminary Concepts
• Objectives of Heat Integration:

 Minimize utilities consumption

 minimize operating cost.

 Minimize number of heat exchangers

 minimize fixed capital cost.

 Process streams are divided

into:
 Hot streams: Have excess
energy
 Cold streams: have deficit in
The onion model
energy
Heat integration (pinch analysis)
 Idea behind Heat Integration:
is performed after considering:
Use available energy in hot streams
• Reactor layer
to heat up cold streams.
• Separation layer: (gas & liquid)
• Recycle structure  Data required: Detailed M & E
Balances (This is why it comes last)
Department of chemical
engineering © Dr. Menwer Attarakih
 Heat Integration of a DME Reactor system
 Non-integrated Reactor:  Integrated Reactor
2

Cold utility R-101

cw

3
Hot utility E-101 4 5

1 E-102

 Flow summary table for a Reactor system

Stream No. 1 2 3 4 5
Temperature (ºC ) 154 250 364 278 100
Pressure ( bar ) 15.1 14.7 13.8 13.6 13.4
This recovery Heat
Vapor fraction 1.0 1.0 1.0 1.0 0.08 exchanger reduces
Mass flow (tonne/h) 10.49 10.49 10.49 10.49 10.49 Q h & Qc
When compared to the
Component mole flow non-integrated reactor
(kmol/h)
Dimethyl ether 1.5 1.5 1.5 1.5 1.5
Methanol 323.0 323.0 323.0 323.0 323.0
water
Department of chemical
3.8 3.8 3.8 3.8 3.8
engineering © Dr. Menwer Attarakih
 The Temperature -Enthalpy Diagram :
Qc Qr Qh
 Construction of the T-H diagram 210
Tct
for two process streams: 191

 Hot stream 172

Ths 153
1. At Tht set Hh = 0 (reference)

Tmin
134
2. Draw a line with slope 1/Chp passing

T(C)
115
though the point (0, Tht)
96

77
 Cold stream
58
(0,Tht)
1. At Tsc set Hc = Qc 39
2. Draw a line with slope 1/Ccp passing 20
0 30 60 90 120 150 180 210 240 270 300
though the point (Qc, Tsc)
H ( kW)
 Determine Qc, Qr & Qh at given Tmin
as shown in the Figure on the right (Qc,Tcs)
hand side
 Tmin is determined by optimization  Qc: Duty of cold utility exchanger
based on the economic analysis of  Qh: Duty of hot utility exchanger
the process
Department at hand
of chemical  Qr: Duty of recovery heat exchanger
engineering © Dr. Menwer Attarakih
(3) UMIST
Design of Heat Exchanger Networks Through Pinch Analysis

Pinch Analysis

Provides the basis for the design of Heat Exchangers &

Utility Networks.
Identifies the minimum practical energy consumption for a
given process design.

The procedure is easy to use and to apply,

it is based on the fundamentals of the first & second
laws of thermodynamics

Traditionally Now

Problem Problem
Design Target (energy, capital)
Design
(4) UMIST
Design of Heat Exchanger Networks Through Pinch Analysis

Track Record is impressive

Energy Saving (15-90%)

Capital Cost (upto 25%)
Improved Flexibility
New Design & Retrofit
Pay back as little as two months
Continues & Batch processes
Applicable for wide range of Technologies

- Composite Cold stream

(5)
Design of Heat Exchanger Networks Through Pinch Analysis UMIST

Heat Recovery Pinch

T Hot Utility T Hot Utility

Cold Utility Cold Utility

H H
1. No Integration 2. Process Heat Recovery
Reduces the Utility
Requirements
(6)
Design of Heat Exchanger Networks Through Pinch Analysis UMIST

QHmin
T Hot Utility T

“PINCH”

Cold Utility QCmin

H H
3. More Process Heat Recovery 4. The PINCH Limits
Process Heat Recovery
(7)
Design of Heat Exchanger Networks Through Pinch Analysis UMIST

T QH T QH +XH

Pinch
(Hot)
Tmin Tmin
Pinch Zero
(Cold)
Qc Qc +XH

H H
The PINCH divided graph into two
5. Economic Choice thermodynamically distinct regions;
of Tmin * QH flows from above the pinch
* Qc flows from below the pinch
* Zero flow of heat across pinch
(4) UMIST
Design of Heat Exchanger Networks Through Pinch Analysis

Track Record is impressive

Energy Saving (15-90%)

Capital Cost (upto 25%)
Improved Flexibility
New Design & Retrofit
Pay back as little as two months
Continues & Batch processes
Applicable for wide range of Technologies
- Optimization of Tmin for the best design
(4) UMIST
Design of Heat Exchanger Networks Through Pinch Analysis

Track Record is impressive

Energy Saving (15-90%)

Capital Cost (upto 25%)
Improved Flexibility
New Design & Retrofit
Pay back as little as two months
Continues & Batch processes
Applicable for wide range of Technologies

- Reflection of CC Grand Composite Curve

(8)
Design of Heat Exchanger Networks Through Pinch Analysis UMIST

Significance of the PINCH

Don’t use cold utilities ABOVE

Don’t use hot utilities BELOW
Don’t transfer heat ACROSS

Obey

External heater above the pinch only, Maximum

External cooler below the pinch only, Heat Recovery
No heat transfer across the pinch.
(9) UMIST
Design of Heat Exchanger Networks Through Pinch Analysis

Divide Problem at the Pinch

Start matching at the Pinch

Observe CPout > CPin

Maximize the load of exchanger

Fill in the rest

(10) UMIST
Design of Heat Exchanger Networks Through Pinch Analysis

Industrial Case Study

100o
COND COND

80o 100o
C1 R1 C2
135o
Data Extraction
140o
Stream CP
Ts(C) Tt (C)
(kW/C)
REB REB
150o 170o
1) Cold 2 20 135

2) Hot 3 170 60
20o
3) Cold 4 80 140
60o
4) Hot 1.5 150 30 30o
(11) UMIST
Design of Heat Exchanger Networks Through Pinch Analysis

100o
COND COND

By Inspection 80o 100o

C1 R1 C2
135o
St 140o
* Hot Utility 240 kW
(QH) = 240 kW
REB REB
* Cold Utility 150o 170o
(Qc) = 280 kW CW 180 kW
HEX 230 kW
30o
CW 100 kW
20o 60o
(12) UMIST
Design of Heat Exchanger Networks Through Pinch Analysis

The question is,

Can we improve this design ? and,
Is there a design which uses less energy from utilities ?

The answer is YES Pinch Analysis

Target : To find the best network of exchangers, heaters,

and coolers, that handle the process streams at minimum
total costs (energy & capital).
(14)
Design of Heat Exchanger Networks Through Pinch Analysis UMIST

Pinch Analysis
T QHmin = 20 kW
170
* Pinch Temp. at 85o
140
* Pinch at 90o (Hot Side)
80o (Cold Side)
90
80 * Total Hot Utility 20 kW
60 Total Cold Utility 60 kW
PINCH ( Tmin = 10o)
30
20
H
0 60 190 490 540

QCmin = 60 kW
(14)
Design of Heat Exchanger Networks Through Pinch Analysis UMIST

-Subtract (5) from all inlet and outlet Hot streams

- Add (5) degrees all inlet and outlet cold streams

To create the 10

- Put all the temperatures in a Descending order

CP 3 1.5 4 2
165
145
140
85
55
25
(15)
Design of Heat Exchanger Networks Through Pinch Analysis UMIST

Mathematically ..? YES Interval heat balances

Add 5 C for Cold streams and subtract 5 C from Hot stream if the delta = 10 C

Hot Utility Hot Utility

Interval Ti-Ti+1  CPc  CPh
Zero 20
165o
20 - 3.0 H = - 60 H = - 60
145o 60 80

5 - 0.5 H = -2.5 H = -2.5

140o 62.5 82.5

55 1.5 H= 82.5 Negative H= 82.5

85o -20 Zero

30 - 2.5 H = - 75 H = - 75
55o 55 75

30 0.5 H = 15 H = 15
25o 40 60

Cold Utility Cold Utility

(15)
Design of Heat Exchanger Networks Through Pinch Analysis UMIST

Heat Exchanger Stream Representation

CP
90o 60o
2 170o 90o 3.0

150o 90o 90o 30o

4 1.5
135o 80o 20o
1 2.0
140o 80o
3 4.0
ABOVE BELOW
PINCH
(16)
Design of Heat Exchanger Networks Through Pinch Analysis UMIST

CP
1 90o
2 170o 3.0

150o 2 90o
4 1.5

135o 125o 80o

St 1 2.0
20 kW 90 kW 80o
140o
3 4.0
240 kW

ABOVE PINCH
(17)
Design of Heat Exchanger Networks Through Pinch Analysis UMIST

CP

1 60o
2
90o 3.0

90o 70o 30o

4 CW 1.5
80o 35o
60 kW 20o
1 2.0
90 kW 30 kW

PINCH BELOW
(18)
Design of Heat Exchanger Networks Through Pinch Analysis UMIST

CP
60o
2 170o 90o 3.0

150o 90o 70o 30o

4 CW 1.5
125o 80o
60 kW
135o 35o 20o
St 1 2.0
20 kW 90 kW 80o 90 kW 30 kW
140o
1 4.0

240 kW
* Hot Utility * Cold Utility
(QH) = 20 kW (Qc) = 60 kW
(19)
Design of Heat Exchanger Networks Through Pinch Analysis

100o
COND COND

80o 100o
C1 R1 C2
135o
140o
20 kW St
REB
REB
150o 170o
125o
90 kW 80o 240 kW
90o 90o
90 kW
30 kW 35o
20o 70o
CW 60 kW

30o
60o
The Complete Design
Minimum Number of Units
Above the pinch
Loops and Energy relaxation
Design of Heat Exchanger Networks Through Pinch Analysis UMIST

Final words

Energy relaxation can be carried out if energy cost

is not the effective element.
Certain designs can generate several Heat Exchanger
Networks (HEN) through PINCH analysis

The selected HEN should have the best energy &

capital cost trade-off.
Case Study Two
5 10 15
X