Heat and Power Integration CHEN 4460 – Process Synthesis, Simulation and Optimization Dr. Mario Richard Eden Department of Chemical Engineering Auburn University Lecture No. 8 – Heat and Power Integration: Targeting October 23, 2006 Contains Material Developed by Dr. Daniel R. Lewin, Technion, Israel
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Heat and Power Integration CHEN 4460 – Process Synthesis, Simulation and Optimization Dr. Mario Richard Eden Department of Chemical Engineering Auburn.
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Heat and Power Integration
CHEN 4460 – Process Synthesis, Simulation and Optimization
Dr. Mario Richard EdenDepartment of Chemical Engineering
Auburn University
Lecture No. 8 – Heat and Power Integration: Targeting
October 23, 2006
Contains Material Developed by Dr. Daniel R. Lewin, Technion, Israel
Lecture 8 – Objectives
Compute the pinch temperatures
Compute the Maximum Energy Recovery (MER) targets using graphical and/or algebraic methods
Given data on the hot and cold streams of a process, you should be able to:
Motivating Example
• What is wrong with this process from an energy viewpoint?
• Recommended text– Seider, Seader and Lewin (2004): Product and Process
Design Principles, 2 ed. Wiley and Sons, NY– Linnhoff et al. (1982): A User Guide on Process
Integration for the Efficient Use of Energy, I. Chem. E., London
• Most comprehensive review:– Gundersen, T. and Naess, L. (1988): The Synthesis of
Cost Optimal Heat Exchanger Networks: An Industrial Review of the State of the Art, Comp. Chem. Eng., 12(6), 503-530
Capital vs. Energy 1:3
• The design of Heat Exchanger Networks (HENs) deals with the following problem:
Given:
NH hot streams, with given heat capacity flowrate, each having to be cooled from supply temperature TH
S to targets TH
T
NC cold streams, with given heat capacity flowrate, each having to be heated from supply temperature TC
S to targets TC
T
Design:
An optimum network of heat exchangers, connecting between the hot and cold streams and between the streams and cold/hot utilities (furnace, hot-oil, steam, cooling water or refrigerant, depending on the required duty temperature)
Capital vs. Energy 2:3
• Optimality – Implies a trade-off between CAPITAL COSTS (cost of
Design a network of steam heaters, water coolers and exchangers for the process streams. Where possible, use exchangers in preference to utilities.
Utilities:
Steam @ 150 oC, CW @ 25oC
30° 120°
180° 80°
130° 40°
60° 100°
ΔH=162
ΔH=160
ΔH=100
ΔH=180
Simple Example - Targets
30° 120°
180° 80°
40°
60°
ΔH=162
ΔH=60ΔH=1813
0°
ΔH=100
100°
Units: 4Steam: 60 kWCooling water: 18 kW
Are these numbers optimal??
Temperature-Enthalpy Diagram
Correlation between Tmin, QHmin and QCmin
More in, More out! QHmin + x QCmin + x
Tmin = 10
Steam
CWC
H
110oC
100oC
T
HQCmin = 30 QHmin = 50
Steam
CW
Tmin = 20
Steam
CWC
H
120oC
100oC
T
HQCmin = 50 QHmin = 70
Steam
CW
The Composite Curve 1:2Temperature
Enthalpy
T1
T2
T3
T4
T5
CP
= A
CP = B
C P =
C
H Interval
(T1 - T2)*B
(T2 - T3)*(A+B+C)
(T3 - T4)*(A+C)
(T4 - T5)*A
Three (3) hot streams
The Composite Curve 2:2
Three (3) hot streams
Temperature
Enthalpy
T1
T2
T3
T4
T5
H Interval
H1
H2
H3
H4
CP = B
CP = A + B + C
CP = A + B
CP = A
H=150
H
180
130
CP = 3.0
80
40
H=50
H=80
CP
= 1
.0
C P = 2
.0
T
Simple Ex. – Hot Composite
30° 120°
180° 80°
130° 40°
60° 100°
ΔH=162
ΔH=160
ΔH=100
ΔH=180
H=150
T
H
180
130
CP
= 1
.0
C P = 2
.0
80
40
H=50
H=80Not to scale!
!
Not to scale!
!
H=232
T
H
120
100
CP = 5.8
60
30
H=36
H=54
CP
= 1
.8
CP
= 1
.8
Simple Ex. – Cold Composite
30° 120°
180° 80°
130° 40°
60° 100°
ΔH=162
ΔH=160
ΔH=100
ΔH=180
H=232
T
H
120
100
CP
= 1
.8
CP = 4.0
60
30
H=36
H=54Not to scale!
!
Not to scale!
!
Thermal Pinch Diagram
T
H
QC,min
QH,min
Tmin
Tpinch,hot
Tpinch,cold
Move cold composite
horizontally until the two curves are
exactly ΔTmin apart
Simple Ex. - Pinch Diagram
0
20
40
60
80
100
120
140
160
180
200
0 50 100 150 200 250 300 350
Enthalpy
Te
mp
era
ture
QCmin = 6 kW QHmin = 48 kW
TCpinch = 60
THpinch = 70
Maximum Energy Recovery (MER) Targets!
The Pinch
The “pinch” separates the HEN problem into two parts:
Heat sink - above the pinch, where at least QHmin utility must be used
Heat source - below the pinch, where at least QCmin utility must be used.
H
T
QCmin
QHmin
“PI NCH”
H
T
QCmin
QHmin
HeatSource Heat
Sink
Tmin
+x
x
+x
Significance of the Pinch
• Do not transfer heat across pinch
• Do not use cold utilities above the pinch
• Do not use hot utilities below the pinch
Algebraic Targeting Method
• Temperature scales– Hot stream temperatures (T)– Cold stream temperatures (t)
• Thermal equilibrium– Achieved when T = t
• Inclusion of temperature driving force ΔTmin
– T = t + ΔTmin
– Thus substracting ΔTmin from the hot temperatures will ensure thermal feasibility at all times
Algebraic Targeting Method
• Exchangeable load of the u’th hot stream passing through the z’th temperature interval:
• Exchangeable capacity of the v’th cold stream passing through the z’th temperature interval:
, 1( )Hu z u z zQ C T T
, 1 1 min min
, 1
( ) (( ) ( ))
( )
Cv z v z z v z z
Cv z v z z
Q C t t C T T T T
Q C T T
Algebraic Targeting Method
• Collective load of the hot streams passing through the z’th temperature interval is:
• Collective capacity of the cold streams streams passing through the z’th temperature interval is:
,H Hz u z
u
H Q
,C Cz v z
u
H Q
Algebraic Targeting Method
• Heat balance around each temperature interval:
1H C
z z z zr H H r
zHeat added by hot streams
Heat removed by cold streams
Residual heat from preceding interval
Residual heat to subsequent interval
HzH
1zr
CzH
zr
Algebraic Targeting Method
• The enthalpy cascade– r0 is zero (no hot streams exist above the first
interval)
– Feasibility is insured when all the rz's are nonnegative
– The most negative rz corresponds to the minimum heating utility requirement (QHmin) of the process
– By adding an amount (QHmin) to the top interval a revised enthalpy cascade is obtained
Algebraic Targeting Method
• The revised enthalpy cascade– On the revised cascade the location of rz=0
corresponds to the heat-exchange pinch point
– Overall energy balance for the network must be realized, thus the residual load leaving the last temperature interval is the minimum cooling utility requirement (QCmin) of the process
Algebraic Targeting Method
Stream TS
(oF)
TT
(oF)
H
(kBtu/h)
CP
(kBtu/h oF)
H1 260 160 3000 30
H2 250 130 1800 15
C1 120 235 2300 20
C2 180 240 2400 40
• Example– Two hot streams and two cold streams
– ΔTmin = 10°F
Step 1: Temperature intervals– Substract ΔTmin from hot temperatures
– 250°F 240°F 235°F 180°F 150°F 120°F
Stream TS
(oF)
TT
(oF)
H
(kBtu/h)
CP
(kBtu/h oF)
H1 250 150 3000 30
H2 240 120 1800 15
C1 120 235 2300 20
C2 180 240 2400 40
Stream TS
(oF)
TT
(oF)
H
(kBtu/h)
CP
(kBtu/h oF)
H1 260 160 3000 30
H2 250 130 1800 15
C1 120 235 2300 20
C2 180 240 2400 40
Algebraic Targeting Method
Step 2: Interval heat balances– For each interval calculate the enthalpy load Hi = (Ti Ti+1)(CPHot CPCold )