EnergyTargetingProcedure Module04 Lecture10

Module04:Targeting
Lecture10:EnergyTargetingProcedure
Keywords:Targeting,HEN,compositecurve,T
min
,

AnimportantfeatureofProcessIntegrationistheabilitytoidentifyPerformanceTargetsbefore
thedesignstepisstarted.TargetingprocedurealsohelpsintheevaluationofalternativeHEN
designs.Forheatrecoverysystemswithaspecifiedvaluefortheminimumallowableapproach
temperature(T
min
),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:FourstreamproblemforloadintegrationandutilitypredictionforT
min
equalto
10C.
Nameofthestream SupplyTemperature
Ts,C
TargetTemperature
Tt,C
CP
kW/C
H
kW
Hot1 140 50 2 180
Hot2 90 40 6 300
Cold1 30 150 2 240
Cold2 70 125 3 165

EnergyTargetingProcedure Module04 Lecture10

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
process through energy targeting procedure. It should be noted that through this process one
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. A discussion in the later part of this lecture will show that one has to pay penalty in
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.

Fig.3.25ShowsbothcompositecurvesputtogetherforproblemgiveninTable3.8
70C
125C
150C
140C
90C
50C
40C
30C
T,C
H,kW
T
min
=10C
Q
HOT,MIN
Q
COLD,MIN
HotPinch

ColdPinch

InternalHeat
Exchange

SourceSection
80C
SinkSection
External
Hotutility

ExternalCold
utility

HotCompositecurve

Cold Compositecurve

BelowthePinch AbovethePinch
PinchPoints
250kW
175kW 230kW
EnergyTargetingProcedure Module04 Lecture10

Becauseofthekinkednatureofthehotandcoldcompositecurves,theyapproachmostclosely
atonepointwhichiscalledthePinch.Pinchisnotapointunlessboththecurvestoucheach
other at a point. In fact, for heat to flow one has to maintain a value of T at pinch which is
calledT
min
.ThusatpinchthereexiststwopointsoutofwhichoneiscalledHotpinchpointand
the other cold pinch point as shown in Fig.3.25. From Fig.3.25 it can be seen that hot utility
demand is 175 kW , cold utility demand is 250 kW and internal heat exchange is 230 kW. The
hot pinch point is at 90C and cold pinch point is at 80C. This is for T
min
C equal to 10C. If
one changes the T
min
value from 10C to a new value then the requirements of cold and hot
utilitywillchangeandsotheinternalheatexchange.TodemonstratetheabovefactT
min
value
ischangedfrom5Cto30Cinthestepsof5CandtheresultsarereportedinTable4.1.

Table4.1Valuesofcold,hotutilitydemandandinternalheatexchangewhenT
min
isaltered.
T
min
,C ColdUtility,kW HotUtility,kW Internal
Exchange,kW
Total Heat
Exchange,kW
5 225 150 255 630
10 250 175 230 655
15 275 200 205 680
20 300 225 180 705
25 310 235 170 715
Fig.4.1Verticalheattransfer
70C
125C
150C
140C
50C
40C
30C
T,C
H,kW
HotCompositecurve

Cold Compositecurve

T
min

HotUtility
10C
ColdUtility
EnergyTargetingProcedure Module04 Lecture10
30 320 245 160 725

FromTable4.1itisclearthatasthevalueofT
min
increases,internalheatexchangedecreases
andthevalueofcoldandhotutilityaswellasvalueoftotalheatexchangeincreases.Duetothe
increaseinthevalueof externalcoldandhotutilitiestheoperatingcostoftheHENincreases.
Further,thedecreaseininternalheatexchangedecreasesthescopeofenergyconservationin
the process. An increase in value of T
min
increases the value of T

available to all the

exchangersintheHEN.
It is known fact that increases in the value of T
min
decreases the heat transfer area as it
provideshighervalueofdrivingforceaspertheequationgivenbelow:
Q=UAT (4.1)
Where
Qloadofexchanger
AHeattransferarea
Uoverallheattransfercoefficient
Ttemperaturedifferenceavailableforheattransfer

However, this conclusion is true only when Q and U remain constant when T
min
increases.
FromTable4.1itisevidentthatwiththeincreaseinT
min
thetotalheatexchangevalue(Q)of
theHENincreases.Thus,thebenefitofreductionofheattransferareaduetoincreaseinT
min

will be nullify to some extent due to increase in the value of total heat exchange at the same
time. Thus T
min
is an important parameter for design as it affects operating as well as fixed
costsofHEN.

ThemostappropriatevalueofT
min
orinotherwordstherelativepositionsofthehotandcold
composite curves is determined by an economic tradeoff between energy and capital. Once
thecorrecteconomicvalueofT
min
isknownthentheenergytargetsintermsofthevaluesof
hot and cold utilities are automatically fixed. The T
min
in general appears at one location
betweenhotandcoldcompositecurvescalledheatrecoverypinch.Aspinchpointisrelated
toT
min
,ithasspecialsignificanceinthedesign.

TheprincipleofPinch
Fig.4.2 (a) shows the heat exchange system separated at pinch . The section above the pinch
worksasaheatsinkasitacceptsheatfromexternalheatingsources(heatutility).Theamount
ofheatrequiredisexactlyequaltoQ
HOTMIN
.Therequiredheatwhichisnecessarytostrikeheat
balanceofthissectionafterhotcompositecurvetransferstheheattocoldcompositecurveis
Q
HOT MIN
. As this section takes heat from outside it is termed as heat sink. With the external
heatingequaltoQ
HOTMIN
thesectionisinheatbalance,i.e.heatrequiredbythecoldstreamis
EnergyTargetingProcedure Module04 Lecture10
satisfiedbyheattransferredfromthehotcompositestreamandtheQ
HOTMIN
fromexternalhot
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
transferring heat to cold compositecurve. Once Q
COLD MIN
is transferred

to externalcold utility
thissectionisalsoinheatbalance.
Thusbothsectionsi.e.abovethepinchandbelowthepinchsectionsareinheatbalanceandno
heat flows through the pinch section. This is true, only if we consider vertical heat transfer in
thewholesectionoftheheatexchangeprocessasgiveninFig.4.1.
However,asshowninFig.4.2(b),ifanadditionalamountofheat,,overandaboveQ
HOTMIN
is
transferredtothe above pinchsection thetotalexternalheatgiven tothissection becomesQ
HOT MIN
+ and then the additional amount of heat ,, flows through pinch ( as both sections
above & below pinch are under heat balance) and increases the cold utility to Q
COLD MIN
+ .
Thus adding more heat than required in the above pinch section is not fruitful instead it is
harmful.Thisfactisexplainedbelow.
When additional amount of heat, , than required amount of heat Q
HOT MIN
, is introduces in
above pinch section then one has to supply appropriate heat transfer area to push it. Further,
the external hot utility cost proportional to is also increased. Thus, total cost in the above
pinchsectionincreasesduetoincreaseinthecostofheatexchangearea(proportionalto)and
alsothe increased inexternalhotutilitycost which isalsoproportional to . Thesameistrue
for below pinch section where the cold utility cost increases proportional to as well as the
cost of heat transfer area also increases proportional to . Thus for every unit of excess heat
one has to provide the required heat transfer area twice once in hot utility side and other in
cold utility side. Thus the penalty is twice for passing additional heat through the system than
required.Thus,B.Linnoffet.alhavecoinedthephraseMorein,Moreout.Thisvitalinsight,
many a times,helpsustodecreasebothutility and fixed costof a heattransferringsystem by
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(Q
HOTMIN
andQ
HOTMIN
)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
EnergyTargetingProcedure Module04 Lecture10
balance extra hot utility of amount has to be added to Q
HOT MIN
and thus total hot utility
requiredtobringthesectionintoheatbalancewillbenowQ
HOTMIN
+.

Fig.4.2SourceandSinksections ofaheatexchangesystem
HeatSource
(a)
T,C
H,kW
T
min
=10C
Q
HOT,MIN
Q
COLD,MIN
HotPinch

Cold
Pinch

External
Hotutility

ExternalCold
utility

BelowthePinch
AbovethePinch
Heat
Sink
HeatSource
(b)
T,C
H,kW
T
min
=10C
Q
HOT,MIN+
HotPinch

Cold
Pinch

External
Hotutility

ExternalCold
utility

BelowthePinch
AbovethePinch
Heat
Sink



Q
COLD,MIN
+
Q
COLD,MIN
+
EnergyTargetingProcedure Module04 Lecture10

HeatSource
(b)
T,C
H,kW
Q
HOT,MIN
HotPinch

Cold
Pinch

External
Hotutility

ExternalCold
utility

BelowthePinch
AbovethePinch
Heat
Sink

Q
COLD,MIN
+
Fig.4.3Effectofinappropriateuseofutilities
HeatSource
(a)
T,C
H,kW
Q
HOT,MIN+
HotPinch

Cold
Pinch

External
Hotutility

ExternalCold
utility

BelowthePinch
AbovethePinch
Heat
Sink

Q
COLD,MIN

EnergyTargetingProcedure Module04 Lecture10

Thiswillincreasesthetotalhotutilitycostaswellasfixedcostofheatexchangerwhichwillnow
transfer Q
HOT MIN
+ heat in place of Q
HOT MIN
. As below the pinch section is under heat
balancethecoldutilityrequirementwillbeQ
COLDMIN
.
Further,ifhotutilityisusedinthebelowpinchsectionby anamountit willdisturbtheheat
balance of this section. Now additional heat amounting to is available in this section to be
cooled.ThiswillincreasethecoldutilityrequirementtoQ
COLDMIN
+tobringtoheatbalance
again. However, the above pinch section which is under heat balance already will only require
externalheatingofQ
HOTMIN
.
Fromtheaboveanalysisfollowingconclusionsaremade.
1. Donottransferheatacrossthepinchasthepenaltyistwice.
2. Donotusecoldutilityintheabovepinchsection
3. Donotusehotutilityinbelowpinchsection
The above faults are generally committed in old designs which were carried out without using
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,IChem
E
,ElsevierLimited,2007.