EnergyTargetingProcedure

Module04

Lecture10

Module04:Targeting Lecture10:EnergyTargetingProcedure Keywords:Targeting,HEN,compositecurve,Tmin,

AnimportantfeatureofProcessIntegrationistheabilitytoidentifyPerformanceTargetsbefore thedesignstepisstarted.TargetingprocedurealsohelpsintheevaluationofalternativeHEN designs.Forheatrecoverysystemswithaspecifiedvaluefortheminimumallowableapproach temperature(Tmin),targetscanbeestablishedfor: 1. EnergyTarget(MinimumEnergyConsumptionthroughexternalheatingandcooling), 2. FewestNumberofUnits(process/processheatexchangers,heatersandcoolers)inthe HEN 3. Fewestnumberofshellsintheheatexchangernetwork(HEN) 4. MinimumTotalHeatTransferAreaoftheHEN 5. CostTargeting(TotalannualcostoftheHEN) Resultsobtainedfromthesetargetsleadthedesigninrightdirectionandhelptosearchfora optimumtopology.

EnergytargetingcanbedonethroughHotandcoldcompositecurves,Grandcompositecurve and Problem Table Algorithm. The present lecture deals with energy targeting using hot and coldcompositecurves. To explain the energy targeting procedure using hot and cold composite curves a problem as given in Table 3.8 and reproduced below from lecture 07 is considered. The hot and cold compositecurvesplacedtogetherisaplotistakenfromFig.3.25andreproducedbelow:

Table3.8:FourstreamproblemforloadintegrationandutilitypredictionforTminequalto 10C. Nameofthestream SupplyTemperature TargetTemperature CP H Ts,C Tt,C kW/C kW Hot1 140 50 2 180 Hot2 90 40 6 300 Cold1 30 150 2 240 Cold2 70 125 3 165

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T,C External InternalHeat Hotutility Exchange Q HOT,MIN 230kW 175kW 150C 140C 125C HotCompositecurve PinchPoints HotPinch 90C Tmin=10C ColdPinch 80C 70C Cold Compositecurve 50C 40C 30C H,kW ExternalCold utility 250kW QCOLD,MIN SourceSection SinkSection BelowthePinch AbovethePinch Fig.3.25ShowsbothcompositecurvesputtogetherforproblemgiveninTable3.8 Once Hot and cold composite curves are known, one can estimate with ease the minimum amount of external heating ( Hot utility) and external cooling(Cold utility) required for the processthroughenergytargetingprocedure.Itshouldbenotedthatthroughthisprocessone targets minimum amount of hot and cold utility that the process demands. However, higher amount of hot and cold utilities ( in comparison to minimum value) can be supplied to the process.Adiscussioninthelaterpartofthislecturewillshowthatonehastopaypenaltyin terms of energy and capital cost if he decides to use higher amount of utilities than that of minimumamount.

The overlap between the hot and cold composite curves represent the maximum amount of heat that can be recovered within the process. The overshoot of the hot composite represents the minimum amount of external cooling required in the process and the overshoot of the cold composite represents the minimum amount of external heating required in the process. This concept is based on vertical heat transfer in the internal heat exchange area as well as at utility areas as shown in Fig.4.1. Energy targeting is a powerful processintegrationconcept.

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Lecture10

Becauseofthekinkednatureofthehotandcoldcompositecurves,theyapproachmostclosely atonepointwhichiscalledthePinch.Pinchisnotapointunlessboththecurvestoucheach other at a point. In fact, for heat to flow one has to maintain a valueof T at pinch which is calledTmin.ThusatpinchthereexiststwopointsoutofwhichoneiscalledHotpinchpointand the other cold pinch point as shown in Fig.3.25. From Fig.3.25 it can be seen that hot utility demandis175kW,coldutilitydemandis250kWandinternalheatexchangeis230kW.The hotpinchpointisat90Candcoldpinchpointisat80C.ThisisforTminCequalto10C.If onechangestheTminvaluefrom10Ctoanewvaluethentherequirementsofcoldandhot utilitywillchangeandsotheinternalheatexchange.TodemonstratetheabovefactTminvalue ischangedfrom5Cto30Cinthestepsof5CandtheresultsarereportedinTable4.1. Table4.1Valuesofcold,hotutilitydemandandinternalheatexchangewhenTminisaltered. Tmin,C 5 10 15 20 25 ColdUtility,kW 225 250 275 300 310 HotUtility,kW 150 175 200 225 235 Internal Exchange,kW 255 230 205 180 170 Total Heat Exchange,kW 630 655 680 705 715 Fig.4.1Verticalheattransfer
70C 50C 40C 30C 10C ColdUtility 150C 140C 125C T,C HotUtility

HotCompositecurve
Tmin

Cold Compositecurve

H,kW

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30

320

245

160

725

FromTable4.1itisclearthatasthevalueofTminincreases,internalheatexchangedecreases andthevalueofcoldandhotutilityaswellasvalueoftotalheatexchangeincreases.Duetothe increaseinthevalueofexternalcoldandhotutilitiestheoperatingcostoftheHENincreases. Further,thedecreaseininternalheatexchangedecreasesthescopeofenergyconservationin the process. An increase in value of Tmin increases the value of T available to all the exchangersintheHEN. It is known fact that increases in the value of Tmin decreases the heat transfer area as it provideshighervalueofdrivingforceaspertheequationgivenbelow: Q=UAT Where Qloadofexchanger AHeattransferarea Uoverallheattransfercoefficient Ttemperaturedifferenceavailableforheattransfer However, this conclusion is true only when Q and U remain constant when Tmin increases. FromTable4.1itisevidentthatwiththeincreaseinTminthetotalheatexchangevalue(Q)of theHENincreases.Thus,thebenefitofreductionofheattransferareaduetoincreaseinTmin willbenullifytosomeextentduetoincreaseinthevalueoftotalheatexchangeatthesame time.ThusTminisanimportantparameterfordesignasitaffectsoperatingaswellasfixed costsofHEN. ThemostappropriatevalueofTminorinotherwordstherelativepositionsofthehotandcold composite curves is determined by an economic tradeoff between energy and capital. Once thecorrecteconomicvalueofTminisknownthentheenergytargetsintermsofthevaluesof hot and cold utilities are automatically fixed. The Tmin in general appears at one location betweenhotandcoldcompositecurvescalledheatrecoverypinch.Aspinchpointisrelated toTmin,ithasspecialsignificanceinthedesign. (4.1)

TheprincipleofPinch
Fig.4.2 (a) shows the heat exchange system separated at pinch . The section above the pinch worksasaheatsinkasitacceptsheatfromexternalheatingsources(heatutility).Theamount ofheatrequiredisexactlyequaltoQHOTMIN.Therequiredheatwhichisnecessarytostrikeheat balanceofthissectionafterhotcompositecurvetransferstheheattocoldcompositecurveis Q HOT MIN. As this section takes heat from outside it is termed as heat sink. With the external heatingequaltoQ HOTMINthesectionisinheatbalance,i.e.heatrequiredbythecoldstreamis

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satisfiedbyheattransferredfromthehotcompositestreamandtheQHOTMINfromexternalhot utility. Similarly Fig.4.2(a) also shows that the section below the pinch works as Heat source as it rejectsheattotheexternalcoldutility.TheamountofheatrejectedtocoldutilityisQ COLDMIN. In this section, hot composite curve has excess heat (Q COLD MIN) available with it even after transferringheattocoldcompositecurve.OnceQ COLD MIN istransferred toexternalcoldutility thissectionisalsoinheatbalance. Thusbothsectionsi.e.abovethepinchandbelowthepinchsectionsareinheatbalanceandno heatflowsthroughthepinchsection.Thisistrue,onlyifweconsiderverticalheattransferin thewholesectionoftheheatexchangeprocessasgiveninFig.4.1. However,asshowninFig.4.2(b),ifanadditionalamountofheat,,overandaboveQ HOTMINis transferredtotheabovepinchsectionthetotalexternalheatgiventothissectionbecomesQ HOT MIN + and then the additional amount of heat ,, flows through pinch ( as both sections above&below pinchareunderheatbalance)andincreasesthecoldutilitytoQ COLD MIN + . Thus adding more heat than required in the above pinch section is not fruitful instead it is harmful.Thisfactisexplainedbelow. Whenadditionalamountofheat,,thanrequiredamountofheatQ HOT MIN,isintroducesin abovepinchsectionthenonehastosupplyappropriateheattransferareatopushit.Further, theexternalhotutilitycostproportionaltoisalsoincreased.Thus,totalcostintheabove pinchsectionincreasesduetoincreaseinthecostofheatexchangearea(proportionalto)and alsotheincreasedinexternalhotutilitycostwhichisalsoproportionalto.Thesameistrue forbelowpinchsectionwherethecoldutilitycostincreasesproportionaltoaswellasthe costofheattransferareaalsoincreasesproportionalto.Thusforeveryunitofexcessheat one has to provide the required heat transfer area twice once in hot utility side and other in coldutilityside.Thusthepenaltyistwiceforpassingadditionalheatthroughthesystemthan required.Thus,B.Linnoffet.alhavecoinedthephraseMorein,Moreout.Thisvitalinsight, manyatimes,helpsustodecreasebothutilityandfixedcostofaheattransferringsystemby eliminatingtheabovediscussederror. An inefficient process always requires more hot utility than the minimum hot utility required and as a consequence will consume more cold utility than required. Thus inefficient systems arescreenedrapidlyonceenergytargets(QHOTMINandQHOTMIN)aredetermined. Further, let us examine what happens when hot utility is used below pinch section and cold utilityisusedintheabovepinchsection.Fig.4.3(a)isdrawnshowtheeffect.Iftheextracold utilityofamountisusedintheabovepinchareawhichisunderheatbalance,itwillcoolthe hot stream or hot utility by amount and will disturb the heat balance. To bring it to heat

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balance extra hot utility of amount has to be added to Q HOT MIN and thus total hot utility requiredtobringthesectionintoheatbalancewillbenowQHOTMIN+.
T,C

Cold Pinch ExternalCold utility
T,C

External Hotutility

Q HOT,MIN

HeatSource

HotPinch

Tmin=10C

Heat Sink

Cold Pinch ExternalCold utility

AbovethePinch
H,kW

QCOLD,MIN
BelowthePinch
(a)

External Hotutility

QHOT,MIN+

HeatSource

HotPinch

Tmin=10C

Heat Sink

AbovethePinch
H,kW

QCOLD,MIN+
BelowthePinch
(b)

QCOLD,MIN+

Fig.4.2SourceandSinksections ofaheatexchangesystem

EnergyTargetingProcedure

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Lecture10

T,C

External Hotutility

QHOT,MIN+

HeatSource

HotPinch

Heat Sink
AbovethePinch

Cold Pinch ExternalCold utility

H,kW

QCOLD,MIN
BelowthePinch
(a)

T,C

External Hotutility

HeatSource
HotPinch

Q HOT,MIN

Heat Sink
AbovethePinch

Cold Pinch ExternalCold utility

H,kW

QCOLD,MIN+
BelowthePinch
(b)

Fig.4.3Effectofinappropriateuseofutilities

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Thiswillincreasesthetotalhotutilitycostaswellasfixedcostofheatexchangerwhichwillnow transfer Q HOT MIN + heat in place of Q HOT MIN . As below the pinch section is under heat balancethecoldutilityrequirementwillbeQCOLDMIN. Further,ifhotutilityisusedinthebelowpinchsectionbyanamountitwilldisturbtheheat balanceofthissection.Nowadditionalheatamountingtoisavailableinthissectiontobe cooled.ThiswillincreasethecoldutilityrequirementtoQ COLDMIN+tobringtoheatbalance again.However,theabovepinchsectionwhichisunderheatbalancealreadywillonlyrequire externalheatingofQHOTMIN. Fromtheaboveanalysisfollowingconclusionsaremade. 1. Donottransferheatacrossthepinchasthepenaltyistwice. 2. Donotusecoldutilityintheabovepinchsection 3. Donotusehotutilityinbelowpinchsection Theabovefaultsaregenerallycommittedinolddesignswhichwerecarriedoutwithoutusing pinchanalysisandhenceprovideopportunitytocorrectthesedesignsandsavefixedaswellas utilitycost. References 1. Linnhoff March, Introduction to Pinch Technology Targeting House, Gadbrook Park,Northwich,Cheshire,CW97UZ,England 2. ChemicalProcessDesignandIntegration,RobinSmith,JohnWiley&SonsLtd. 3. Ian C Kemp, Pinch Analysis and process integration, a user guide on process integrationforeffectiveuseofenergy,IChemE,ElsevierLimited,2007.