Net Energy at Every Interval

Stream
1
2
3
4

PROCESS ENGINEERING

Condition
Hot
Hot
Cold
Cold

FCP, BTU/h F
1000
4000
3000
6000

Tin (F)
250
200
90
130

Tout (F)
120
100
150
190

Q available BTU/h
130000
400000
-180000
-360000

NET HEAT

-10000
Q (BTU/h)

FCP=1000

HENS Heat Exchange

Network Synthesis

250 F

H1

250 F

240 F

200 F

190 F

150 F

140 F

100 F

90 F

50000

FCP=4000

H2

200 F

FCP=6000

- 40000

FCP=3000

3
4

160 F
140 F Pinch

C2

ALVARO ORJUELA

- 80000
40000

120 F

5
100 F

C1

20000

- 10000

Heat Cascade Table

Cascaded
heat

Available
heat

FCP=1000

Required
heat

H1

530000

250 F

H2

480000

200 F

180000
80000
0

150 F

140 F

180000

C2 60000
100 F

90 F

Adding 70000 to each value in the cascaded heat column

H1

60000

C1

180000
120000

FCP=6000

60000

250 F

50000

-80000
40000
20000

240 F

FCP=4000

-40000
360000

Net
heat

FCP=1000

600000

190 F

100000
80000

Cascaded
net heat

50000

240000

100000

Net
heat

200000
280000

Cascaded
heat

240 F

FCP=4000

50000

Grand Composite Data

H2

10000
-70000

200 F

190 F

150 F

-10000

140 F

-80000

FCP=3000
100 F

220/
210/
200/
190/

Hot
utility
required
70000

T (F)

T (F)

230/

HOT
COLD

180/
170/
160/
150/
140/
130/
120/
110/
100/
90/
80/

100

200

300

400

Enthalpy (BTU/h)

500

50000

120000

40000
20000

90 F

C1

FCP=6000

10000
-70000

80000
0

-30000

40000

-10000

60000

Grand Composite Curve

240/

70000

FCP=3000

Hohmann/Lockhart
Hohmann/Lockhart Composite Curve

60000

-40000

C2

Cold
utility
required

Grand
composite

50000

-30000

Then, we add to each value in cascaded net heat the

amount of heat required for the minimum negative value to
be zero (70000)

250
240
230
220
210
200
190
180
170
160
150
140
130
120
110
100
90

Cascaded
net heat

600
Millares

250
240
230
220
210
200
190
180
170
160
150
140
130
120
110
100
90

50000

-40000
-80000
40000
20000

20

40

60

80

100

Enthalpy (BTU/h)

120

140
Millares

Grand Composite Curve

Grand Composite Curve

A line that moves downward to the right (negative slope) is

a net heat source

Whenever there is a heat source segment just above a heat

sink segment, we call it a rightright-facing nose
nose
Heat source

A line that moves downward to the left (positive slope) is a

net heat sink

Heat sink

We can integrate noses (slice off the nose). Use heat

available to supply heat required. At lines intersection there
is still a driving force (defined Tmin)
Remove with utilities
Integrate these streams

Grand Composite Curve

Grand Composite Curve

We can do one overall slice, or could have sliced recursively

to obtain the same result

The part of the curve that is left after we slice off rightright-facing
noses provide us the coldest temperatures at which we can
provide needed steam (or hot fluid), and the hottest
temperatures at which we can provide needed cooling
utilities for a problem
T

T
Heat sink

Heating service
Cooling service

Pinch

Heat source

Heating service
Cooling service

Heat sink
Heat source

We can not do heat integration across the pinch

HENS divided in two zones: above and below the pinch
Number of alternative configurations grow as N!, where N is
the number of exchanges
If we have 10 exchanges, 6 above the pinch and 4 below
the pinch, the number of alternative configuration reduces
as: (6!x4!)/10! =17280/3628800 = 1/210

Heat sink
Heat source
Heat sink
Slice off noses
H

Grand Composite Heuristics and

limitations

Grand Composite Curve

240/
230/

T (F)

220/
210/
200/
190/
180/
170/
160/
150/
140/
130/
120/
110/
100/
90/
80/

250
240
230
220
210
200
190
180
170
160
150
140
130
120
110
100
90

Heating utility
Cooling utility

20

40

60

80

100

Enthalpy (BTU/h)

Pinch

120

140
Millares

Do not transfer heat across the pinch

Add heat only above the pinch
Cool only below the pinch
Always add heat at the lowest possible temperature level
relative to the process pinch (cheaper heating service)
Always remove heat at the highest possible temperature level
relative to the process pinch (Heat recovery)
Cp is not constant
When phase changes occurs, Q=F
Q=F (assumed FCP)(
)(T=1)
T=1)
When mixtures change phase, it occurs in a temperature
range
Flows and temperatures of streams depend on the overall
optimized analysis of the process.
If a stream is used to supply heat in a reboiler,
reboiler, the optimum
reflux ratio of that column will change. The process is iterative
iterative

Minimum number of exchangers

Sources

Hot Utility
70 BTU
70

H2
400 BTU

H1
130 BTU
110

C1
180 BTU

20

340

Hot Utility
230 BTU

Sources

C2
360 BTU

Assume that heating and cooling loads, and the minimum

utilities were calculated with second law analysis (cascade
analysis and grand composite curve)
Ignore the minimum approach of temperature and only
consider first law
How many paths (heat exchangers) are required to move
heat from sources to sinks? (assume no independent
problems and no loops)

C1
180 BTU

Sources

Hot Utility
70 BTU

Hot Utility
70 BTU
70

Sinks

C1
180 BTU

110

20
C2
360 BTU

340

Independent
Problems

220

C2
360 BTU

Q
70-Q

H1
130 BTU
20-Q

H2
400 BTU
340

Loop

60

110+Q

C1
180 BTU

C2
Cold Utility
360 BTU
60 BTU
Number of exchangers (NE) = Number of streams (NS) + Number of utilities (NU) +
Number of loops (NL) Number of independent problems (NIP)
Sinks

Heat Exchangers Required

FCP=1000

H2
400 BTU

H1
130 BTU

180

Cold Utility
220 BTU
Number of exchangers (NE) = Number of streams (NS) + Number of utilities (NU)
Number of independent problems (NIP)

Minimum number of exchangers

Sources

130

Sinks

H2
400 BTU

H1
130 BTU

230

60

Cold Utility
60 BTU
Number of exchangers (NE) = Number of streams (NS) + Number of utilities (NU) -1
Sinks

Minimum number of exchangers

H1

250 F

240 F

200 F

190 F

150 F

140 F

100 F

90 F

FCP=4000

60

H2

Cold Utility
60 BTU

FCP=6000

FCP=3000
140 F Pinch

Number of exchangers (NE)= Number of streams (NS) + Number of utilities (NU) -1

Above pinch: NE = NS + NHeating - 1 = NS

C2
C1

Above pinch: NE = NS + NHeating - 1 = NS

NE = NS = 4

Below pinch: NE = NS + NCooling 1 = NS

Below pinch: NE = NS + NCooling 1 = NS

NE = NS = 3

Area Estimates of Heat Exchangers

With cascaded heat we can estimate utility costs
(operation costs) of the plant without a complete design of
the heat exchanger network
What about capital costs?
Consider the composite diagrams (T vs. H)
Draw a vertical line whenever a change of slope in
composite hot or cold lines is observed
Each interval represents a heat exchanger
From the graph we can read the heat duty and the
temperatures of the heat exchanger
If hot and cold curves correspond to a single stream we
can estimate individual heat transfer coefficients as well as
overall coefficients

Temperature Interval

250 F

200 F

160 F
140 F

H1
H2

250 F

240 F

200 F

190 F

150 F

140 F

100 F

90 F

120 F
100 F

C2
C1

T (F)

Number of Streams in Composite Curve

Area Estimates of Heat Exchangers

Overall coefficient including fouling factor

250
240
230
220
210
200
190
180
170
160
150
140
130
120
110
100
90

HOT
COLD

1
1
1
= +
U hi h0

The area of the heat exchanger is given by

2
Cold
utility
required

2
1

60000
2

Hot
utility
required

However multiple streams are present in each interval

For example in our problem we have 6 intervals and
different number of streams in each one of them

1
1

100

200

300

400

500

600
Millares

Enthalpy (BTU/h)

Area Estimates of Heat Exchangers

Consider an interval where two hot streams (H1 and H2)
are matched against two cold streams (C3 and C4), so
there are two possibilities of matching
H1 and C3, H2 and C4
1/h1
T2

T2

T1

1/h3

1/h4

H1 and C4, H2 and C3

Total heat load and the loglog-mean temperature driving force

for each heat exchanger will be the same
Overall heat transfer coefficients change

1
1
1
= +
U1 h1 h3

A = A1 + A2 =

1/h1

1/h2
T2

T1
1/h4

T2

T1

H1 and C4, H2 and C3

1
1
1
= +
U1 h1 h4

Q
Q
Q 1
1
+
=
+

U1TLM U 2 TLM
TLM U1 U 2

A=

Q 1
1
1
1
+
+
+
TLM h1 h4 h2 h3

This result is general, so we can write an expression for

the total area in the interval
A=

A=

Q HOT 1 COLD 1

+
TLM
hi
hk
k
i

Q 1
1
1
1
+
+
+

TLM h1 h3 h2 h4

Area Estimates of Heat Exchangers

1
1
1
=
+
U 2 h2 h3

1
1
1
=
+
U 2 h2 h4

Q
Q
Q 1
1
+
=
+

U1TLM U 2 TLM
TLM U1 U 2

1/h3

Area Estimates of Heat Exchangers

A = A1 + A2 =

Area Estimates of Heat Exchangers

H1 and C3, H2 and C4

1/h2

T1

Q
U TLM

70000

A=

interval

A=

Q
T
intervals LM

HOT 1 COLD 1

+

hi
hk
k
i

This result does provide a good estimate of the total area

required for the heat exchanger network
The area is a good indicator of installed cost of a heat
exchanger
This is an approximation, and do not give the same result
obtained by designing an specific heat exchanger network
This shortcut procedure is useful to find optimal process
flows in the heat exchanger network with respect to the
capital and operating costs
Detailed design and costing is still required at the end!!!

Capital Cost calculation

Capital cost of Heat Exchangers

Capital cost = f (Area)

Calculate total area above the pinch

Calculate total area below the pinch
You know how many heat exchangers are required above
the pinch and below the pinch (NS)
Total area above the pinch divided by number of heat
exchangers above the pinch will provide the average area
of each equipment
The same is done below the pinch
Capital cost is estimated as a function of the area
Optimal heat exchanger network (minimum capital +
operating costs) with respect to Tmin was defined without
designing the whole heat exchanger network
But how the heat exchanger network looks like?