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2 Process Integration Lecture 2

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2 Process Integration Lecture 2

Uploaded by

Gebrekiros Araya
Copyright
© © All Rights Reserved
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College of Engineering

Department of Chemical Engineering

Process Integration and Optimization

Part I:Process Integration


Lecture 2
Amsalu G.
Targets for Energy Recovery

 The Target of any industrial process designer is to maximize


the process-to process heat recovery and to minimize the
utility (energy) requirements.

 To meet the goal of maximum energy recovery or minimum


energy requirement (MER) an appropriate heat exchanger
network (HEN) is required.
…Cont’d

Selection of Initial ΔTmin value


A few values of ΔTmin based on Linnhoff March’s application
experience are tabulated below for shell and tube heat exchangers.

Table1. Typical ΔTmin values


Composite Curves

 Composite curves were developed for heat recovery


targeting (Linnhoff et al., 1982).
 One hot composite stream represents all the hot process
streams, while one cold composite stream represents all the
cold process streams.
 In essence, the hot composite stream represents a single
process heat source, while the cold composite stream
represents a single process heat sink.
…Cont’d
Combined Composite Curves are used to predict targets for;
 Minimum energy (both hot and cold utility) required.

 Minimum network area required, and

 Minimum number of exchanger units required.

 ΔTmin can be measured directly from the T-H profiles as being


the minimum vertical difference between the hot and cold
curves. This point of minimum temperature difference
represents a bottleneck in heat recovery and is commonly
referred to as the “Pinch”
…Cont’d

 Reading accurate information from such diagrams can be


somewhat difficult, which is why numerical methods are
often preferred.

 The real advantage of such graphical diagrams, however,


is that they provide an overview of the system and they
contribute strongly to the understanding of the problem.
…Cont’d
Stream Data
 The stream data chosen to illustrate the construction of the
Composite Curves. The following minimum elements are
necessary: Stream or segment temperatures are: Supply TS℃,
and Target TT℃.

𝐾𝑊
 Heat capacity flow rate(CP ): the product of FxCP (mass
℃
flow rate Kg/sec by the mass heat capacity KJ/Kg℃)

∆H
CP=
∆T
Where: ∆H is the enthalpy variation over the temperature
interval ∆T. Conversely, Enthalpy Change (∆H) associated with
a steam passing through the exchanger is given by first law of
thermodynamics.
…Cont’d

 First law energy equation: H = Q ± W

 In a heat exchanger no mechanical work is being performed

 W=0

 The above equation simplified to: H = Q where Q represent the


heat supply or demand associated with the stream .

 It is given by the relationship Q = CP × (TT − TS)

 Enthalpy Change, ∆H = CP × (TT − TS)…………… Eq


Temperature-Enthalpy (T - H) Diagrams

 Assume one heat  These are alternative


exchanger. representations
…Cont’d
 Assume one heat exchanger and a heater
…Cont’d
 Assume one heat exchanger and a cooler
…Cont’d
 Two hot-one cold stream
…Cont’d
…Cont’d
 Moving composite curves horizontally
…Cont’d
…Cont’d
Graphical Procedure

 Fix ΔTmin (HRAT)

 Draw the hot composite curve and leave it fixed

 Draw the cold composite curve in such a way that the smallest
temperature difference is equal to ΔTmin

 The temperature at which ΔT = ΔTmin is the PINCH

 The non-overlap on the right is the Minimum Heating Utility


and the non-overlap on the left is the Minimum Cooling Utility

 Show below Example ∆Tmin 10℃


…Cont’d

Stream Type F*CP


Reactor 1 feed Cold 20 180 32.0 0.2
Reactor 1 product Hot 250 40 -31.5 0.15
Reactor 2 feed Cold 140 230 27.0 0.3
Reactor 2 product Hot 200 80 -30.0 0.25
…Cont’d
…Cont’d
…Cont’d
Problem Table Algorithm for minimum utility calculations

 Graphical constructions are not the most convenient means


of determining energy needs.
 A numerical approach called “Problem Table Algorithm”
PTA was developed by Linnhoff & Flower (1978) as a means
of determining the utility needs of process and the location
of the process Pinch.
 The PTA lends itself to hand calculations of the energy
targets.
…Cont’d
Example 1: ∆Tmin 10℃

Stream Type F*CP


Reactor 1 feed Cold 20 180 32.0 0.2

Reactor 1 product Hot 250 40 -31.5 0.15

Reactor 2 feed Cold 140 230 27.0 0.3

Reactor 2 product Hot 200 80 -30.0 0.25


…Cont’d
Procedures:

1. Convert the actual stream TO (Tact) into interval TO (Tint) by


subtracting half the minimum temperature difference from the hot
stream temperatures, and by adding half to the cold stream
temperatures:

∆𝑻𝒎𝒊𝒏
 Hot streams Tint = Tact −
𝟐

∆𝑻𝒎𝒊𝒏
 Cold streams Tint = Tact +
𝟐

2. Note any duplicated interval temperatures. These are bracketed


…Cont’d
3. Rank the interval temperatures in order of magnitude, showing the
duplicated temperatures only once in the order

4. Carry out a heat balance for the streams falling within each
temperature interval: For the nth interval

5. "Cascade" the heat surplus from one interval to the next down the
column of interval temperatures
 Cascading the heat from one interval to the next implies that the
temperature difference is such that the heat can be transferred
between the hot and cold streams.
…Cont’d

 The presence of a negative value in the column indicates that the


temperature gradient is in the wrong direction and that the
exchange is not thermodynamically possible.

 This difficulty can be overcome if heat is introduced into the top


of the cascade.

 Introduce just enough heat to the top of the cascade to eliminate


all the negative values
…Cont’d

 Or cascade diagram illustrates the amounts of available energy, in


excess of that required by process streams, at each temperature
level in the temperature interval diagram.

 The cascade diagram is useful for visualizing how excess energy


is cascaded downwards to heat lower temperature streams.

 It is also useful for identifying where the network pinch occurs.


…Cont’d
Step 1: Convert the actual temperature in to interval temperature (Tint)

Tact Tint
Cold 20 180 25 185
Hot 250 40 245 35
Cold 140 230 145 235
Hot 200 80 195 75

Step 2: Note any duplicated interval temperature. These are bracketed


…Cont’d
Step 3: Rank the interval temperatures in order of magnitude,
showing the duplicated temperatures only once in the order
Grid Diagram
…Cont’d
Step 4. Carry out a heat balance for the streams falling within each
temperature interval: For the nth interval.
…Cont’d

 Cascade the heat surplus from one interval to the next


down the column of interval temperature
245……………0Kw(-)…………………………………………………………………..7.5Kw (+)
235……………..-1.5………………..1.5…………………………………………………….9
195……………..6.0………………..-4.5………………………………………………..…..3
185…………....-1.0……………....-3.5…………………………………………………....4
145……………….4.0……………….-7.5…………………………………………………...0
75...................-14…………...…..6.5…………………………………………………..14
35………………...2.0……………..…4.5…………………………………………………..12
25………………….2.0…………….…2.5…………………………………………………..10
…Cont’d
…Cont’d
Exercise:
The End of Lecture 2!!!

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