Supertargeting Module04 Lacture22

Module04:Targeting
Lecture22:CosttargetingforoptimalT
min
(Supertargeting)
Keywords:Supertargeting,hotutility,coldutility,HEN,TAC,operatingcost,

The selection of T
min
values warrants some discussion. In heat recovery problems having a
pinch, the utility requirements are always sensitive to the selection of T
min
. Further, for any
heatrecoveryproblem,thechoiceofT
min
affectstheshapeoftheprocesssource/sinkprofile
andthusaffectstheheatexchangernetworktopology.Duetothisthefixedcostcomponentas
wellastheoperatingcostcomponentoftheHENvarieswiththeselectionofT
min
.

ItisfactthatthelowervalueofT
min
usuallyreducestheutilitycostbyincreasingtheprocess
toprocessheattransfer.However,atthesametimeitincreasesthearearequirementforHEN
duetolowdrivingforce.ThiscreasesthefixedcostoftheHEN.Thusthereisatradeoff.Since
fixed cost and operating cost( utility cost) are expressed in terms of different time scales, it is
necessary to find a basis for joining these to find a optimum value of T
min
. The selection of
T
min
affectsthecostinseveralwaysasgivenbelow:

IfT
min
isreducedthen:

1. Theamountofhotandcoldutilityreducesandthusitscost.
2. Theamountofprocesstoprocessheatexchangeincreasesandthustherequiredareaof
heatexchanger.Thisincreasesthefixedcost(capitalcost)oftheHEN.
3. The overall temperature driving force ( T) of the HEN decreases and thus the area of
the heat exchangers present in HEN increases increasing the fixed cost of heat
exchangers.
4. Loads of heaters andcoolers decrease , thereby its fixed cost decreases. However, the
increases in the cost of heat exchangers transferring process heat invariably outweighs
thereductioninheaterandcoolercosts.

Hence,themaintradeoffisbetweentheenergycostreductionandfixedcostincrease.The
fixedcostisexpressedforthetotallifeperiodoftheheatexchanger.Theyearlyfixedcostis
expressedasdepreciationcostperyearandischargedforthecompletelifeperiodofthe
equipment.Theutilitycosts(operatingcost)arechargedonyearlybasis.(Rs./year,$/year).
Boththecostscanbeaddedifthetimescaleselectedisoneyear,i.e.takedepreciationvalue
ofthefixedcostwhichisexpressedperyearandadditwithutilitycostwhichisalsoexpressed
peryear.ThetotalcostthusobtainediscalledTotalAnnualCost(TAC).NowforeveryT
min

selectedonecanestimatethevalueofTAC.IfforalargenumberofT
min
valuesTACvaluesare
plottedonecangetavalueofT
min
whichiscalledoptimumT
min
atwhichTACisminimum.
ThisprocessofdeterminingoptimumT
min
basedoncosttargetingiscalledSupertargeting.
Innutshell,introductionofcostdataearlierinthedesignprocedureandapplicationoftotal
annualcosttargettofindtheoptimumT
min
aheadofdesignisreferredtoassupertargeting.
TjoeandLinnhoff(1986)wasfirsttodevelopSupertargetingmethod.

Let us consider the following example consisting of two hot streams (H1 & H2) and two cold
streams(C1&C2)asshownintheTable22.1belowtodemonstrateSupertargeting:

Supertargeting Module04 Lacture22

Table22.1Streamandutilitydata
Stream
T
in
T
out
F h
(
0
C) (
0
C) (kW/
0
C) (kW/m
2
/
0
C)
H1 200 80 30 0.15
H2 240 60 40 0.10
C1 40 240 35 0.20
C2 120 300 20 0.10
CU 25 40 0.50
HU 325 325 2.00

For the above problem (Table 22.1 ) grand composite curves for T
min
of 10
0
C and 20
0
C are
drawnandshownbelowinfig.1(a)and(b)respectively.

HotUtility=1550kW
ColdUtility=2550kW
T
min
=10
0
C
Fig.22.1(a)GrandcompositecurvefortheaboveproblematTmin=10
0
T
min
=20
0
C
HotUtility=2100kW
ColdUtility=3100kW
Supertargeting Module04 Lacture22
Fromtheabovediagram(Fig.22.1(a)&(b)),thehotandcoldutilityrequirementsfortheabove
twocasesareshowninTable22.2:

Table22.2HotandColdutilityrequirementswhenT
min
valuesare10
0
C&20
0
C
T
min
(
0
C) HotUtility(kW) ColdUtility(kW)
10 1550 2550
20 2100 3100

Thus,fromtheTable22.2,onecanseethatforhighervalueofT
min
higherarethehotandcold
utility requirements and therefore, it appears obvious that one should have as low T
min
as
possible to obtain maximum energy exchange or minimum utility cost. However, there is a
negative side to the selection of low T
min
. The surface area required for a heat exchange is
givenbytherelationship,Eq.22.1:

A =

01
LM
(22.1)
Where,
A=Heattransferareainm
2

U=OverallheattransfercoefficientinkW/m
2
K
I
LM
=Logmeantemperaturedifference.

Eq.22.1 clearly indicates that the heat transfer area is inversely proportional to the log mean
temperaturedifference.TheformoftheT
LM
equation,Eq.22.1issuchthatitsvalueiscloseto
T
min
.

I
LM
=
(1
h1
-1
c2
)-(1
h2
-1
c1
)
In (
T
h1
-T
c2
T
h2
-T
c1
)
(22.2)

Hence, lower T
min
values result in larger and more costly heat exchangers as it tends to
increase the area of HEN. Therefore, it is important to choose the right value of T
min
for
networkdesign. This canbe done by costtargetingfor optimumvalueof T
min
.This processis
called Supertargeting. For super targeting the TAC ( Total annual cost) value of the HEN is
computed for different T
min
values and that T
min
value is selected for design of HEN which
providedminimumTAC.

Now,forthe4streamproblemgiveninTable22.1,heatexchangerareaasafunctionofT
min

arecomputedasshowninFig.22.2ThevaluesofT
min
selectedforcomputationare5,10,15,
20, 25, 30, 35 and 40C. From the Fig. it can be seen that the exchanger area of HEN rises
sharply (asymptotically) for the lower values of T
min.
However, the relationship between the
T
min
and hot as well as cold utility amount is different. It rises linearly with T
min
as evident
fromFig.22.3

Supertargeting Module04 Lacture22

Fig.22.2VariationofMinimumExchangerareawithT
min

Fig.22.3VariationofenergyrequirementwithT
min

Supertargeting Module04 Lacture22

EstimationofcostofHEN
Also,thecostofheatexchangervarieswiththeheatexchangerareaaccordingtotherelation:
Costofheatexchanger=a+b*A
c

Where,
A=Heatexchangerarea
a, b, c = cost law constants that vary according to materials of construction, pressure
ratingandtypeofexchanger.

Usingthefollowingcoefficientsfortheheatexchangers:
a) Costofheatexchangers&coolers($yr
1
)=15000+50[Area(m
2
)]
0.9

b) Costofheaters($yr
1
)=15000+80[Area(m
2
)]
0.9

TheservicelifeoftheexchangersintheHENaretakentobe5years.

Cost$/yr
Fig.22.4VariationofannualcostofHENwithT
min
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The variation of annual fixed cost(capital cost) with T
min
is shown in Fig.22.4 The cost of the.
hotutilityandcoldutilityaregivenbelow:
a) Costofcoolingutility($kW
1
yr
1
)=5
b) Costofheatingutility($kW
1
yr
1
)=80
Usingtheabovevaluesofutilitiescost,Thecombinedcostofutilitiesperyeariscomputedfor
differentspecified values ofT
min
and areplotted inFig.22.5whichshowsalinearrelationship
betweenannualutilitycostandT
min
.
The total cost can be obtained by the summation of the annual operating cost and annual
capitalcost(CalledTAC)forspecifiedvaluesofT
min
asshowninFig.22.6.Thisfigureshowsall
the cost components i.e. capital cost, operating cost and total cost. Table 22.3 also shows this
information.

Fig.22.5Variationofannualoperatingcost withT
min

Cost$/yr
Supertargeting Module04 Lacture22
Table22.3DifferentcostcomponentsofHENasafunctionofT
min

T
min
(
0
C) Capitalcost($/yr.) Operatingcost($/yr.) Totalcost($/yr.)

5 148362 177375 325737
10 118419 200750 319169
15 103354 224125 327479
20 93970.4 247500 341470
25 87492.5 270875 358367
30 82736.3 294250 376986
35 79097.2 317625 396722
40 76229.6 341000 417230

From Fig and Table . It is evident that at T

min
= 10
0
C the value of TAC is minimum ($
319169/yr).Thus,theoptimumvalueofT
min
=10
0
C.PleasenotethatSupertargetingismuch
less exact than energy targeting, because there are many uncertainties which creeps into the
computation such as error in the estimation of heat transfer coefficients, total area of a
exchangernetworkanditscosts.However,wenotethatthetotalcostcurvehasarelativelyflat

Fig.22.6VariationofTACwithT
min

TAC($/yr.)
Supertargeting Module04 Lacture22
optimum,sothereisafairamountofflexibility.AslongastheselectedT
min
isnotexcessively
smallorlarge,areasonabledesigncanbeobtainedbyusingagoodestimateforTmin,atleast
for the initial stages. It should be noted that the optimum T
min
is problem specific and is
reducedbyhigherenergycostsand/orbylowercapitalcosts.
References
1. Tjoe,T.N.&Linnhoff,B.(1986).UsingPinchtechnologyforprocessretrofit.Chemical
Engineering,93,47.
2. B.LinnhoffandS.Abroad,Supertargntins:Optimumsynthesisofenergymanagement
systems.ASMEWinterMeeting,Anaheim,December1986