Professional Documents
Culture Documents
Dr Ir François Maréchal
LENI (Laboratory of Industrial Energy Systems)
FM_07/ 2000
Heat requirements
Ṁ cp = 6kW/K Ṁ cp = 3kW/K
FM_07/ 2000
Heat recovery heat exchanger
• Investment
O2
C – Exchangeur
O1'
– Connections
I1 I1' I2
E1 H REA – Control system
• Energy saving
O1
– Hot utility (H)
T(°C) Heat recovery – Cold utility C
Hot utility
• What is the best size of the
175°
O1 heat exchanger ?
150°
I2 • Size
120° O1'
I1' • Cost estimation
DTmin
100° • Benefit
O2 I1
70°
Cold utility
FM_07/ 2001
O2
C !2
O1' δQ
I1 I1' I2 = UA
E1 H REA (Th − Tc )
1
O1
dQ
For= U · dA
constant mcp· (Th − Tc )
T(°C) Heat recovery
Hot utility 1 1 e 1
175° Q ==U · A
+ · DT
+ lm
O1
DT1
150° U Uc λ Uh
I2
120° O1'
I1'
Q=U · A · DT
DT − DTlm
DTmin DT2 1 2
100°
DTlm = DT1
O2 I1 ln( DT 2
)
70° ! "
1 kW 1 e 1
Cold utility
2o
= + + +R
U m C hc λ hf
100+100 300-100 50+100 H(kW)
FM_07/ 2001
Number of transfer units NTU
UA UA
NTU = =
min(Ṁh cph , Ṁc cpc ) (Ṁ cp)min
Counter current
(Ṁ cp)min
Q̇ 1 − exp(−N T U [1 − (Ṁ cp)max
])
!= =
(Ṁ cp)min (Ṁ cp)min
Q̇max 1− (Ṁ cp)max
exp(−N T U [1 − (Ṁ cp)max
])
FM_07/ 2001
Investment estimations
• Different level of detail
C S 0.6
=( )
Cref Sref
Offer call
Detailled design
FM_07/ 2000
Estimating investment cost
n
Ca " Sa % " Ix % C n "I %
= $ ' * $ ' ( Ca = bn * ( Sa ) * $ x '
Cb # Sb & # Iy & Sb # Iy &
Ca Coût de l'équipement de taille Sa acheté l'année x
Cb Coût de l'équipement connu de taille Sb acheté l'année y
n exposant pour le type d'équipement concerné
Ix index des équipements pour l'année x
• Statistiques disponibles
– Corrélations pour les équipements
• E.g. Turton et al.
– Index :
• Marshall & Swift Equipment Cost Index
• CEPCI : Chemical Engineering Plant Cost Index
FM_07/ 2000
2003 402 50
2004 444.2 0
2005 466.3
7
93
94
95
96
97
98
99
00
01
02
03
04
05
5
19
19
19
19
19
19
19
20
20
20
20
20
20
19
19
FM_07/ 2000
Installed cost
• Application d’un facteur global
ne
Ci = F * " Cai
i =1
FM_07/ 2000
Economical value
• Future value of a given value P after n years
F = P * (1 + i) n
F Valeur de P après n années avec un taux d'intérêt i
• Future value of an annual income B after n years
n
r"1
$ (1+ i )n " 1 '
F = # B * (1 + i) = B * & )
r =1 &% i )(
F Valeur après n années d'une rentrée d' argent annuelle
constante B avec un taux d'intérêt i
• Present value of an annual income B after n years
F # (1+ i )n " 1 & # 1 & # (1 + i) n " 1&
P= = B*% (* % n ( = B*% n (
(1 + i) n %$ i (' %$ (1 + i) (' %$ i (1 + i) ('
P Valeur actualisée d'une rentrée d'argent annuelle
consante B avec un taux d'intérêt i après n années
FM_07/ 2000
Evaluation d’un projet
• Coût actualisé
(1 + i)n − 1
N P V = I + CO ∗ (CHF)
i(1 + i)n
facteur d'actualisation (ans) en fonction de la duree et du taux d'intérêt
12
f(5,x)
f(6,x)
11 f(7,x)
f(8,x)
10 f(9,x)
f(10,x)
f(11,x)
9 f(12,x)
f(13,x)
8 f(14,x)
f(15,x)
ans
3
0.04 0.06 0.08 0.1 0.12 0.14
taux d'intérêt
FM_07/ 2000
Operating cost np
!
• Operating time p=1
time(p).(
n
! rm
crm (p).Ṁrm
+
(p)
• Raw materials rm=1
nprod
!
−
cprod (p).Ṁprod (p)
• Sellings −
prod=1
• Resources +
n
! res
cres (p).Ṁres
+
(p)
res=1
• Electricity −c− −
grid (p).Ėgrid (p)
• Emissions
n
! em
+ cem (p).Ṁem−
(p)
• Man power
em=1
˙ work
+cwork .M an hours
• Taxes )
+M aintenance
+T axes
FM_07/ 2000
Project Benefit
FM_07/ 2000
Rentabilité de projets
"I
Temps de retour = (an)
B
$ (1 + i) n # 1'
Bénéfice actualisé = B & n ) # "I * 0 (CHF)
&% i (1+ i ) )(
$ i(1 + i) n '
Bénéfice annuel actualisé = B # "I & n )* 0 (CHF / an)
&% (1 + i) # 1)(
$ (1 + i* )n # 1'
Taux d'actualisation du projet : i* tel que : B & * n
) # "I = 0
& i (1+ i * ) )
% (
FM_07/ 2000
Heat recovery
O2
C
O1'
I1 I1' I2
E1 H REA
O1
∆Tmin
120° O1'
DTmin I1'
100°
O2 I1
70°
Cold utility
FM_07/ 2000
m
˙ 2 * cp2 = 6 kW °C
T 3 = T 4 + DT min Energy
m˙ *cp1 * (T1 " T 3) 15000
T2 = 1 + T4
m˙ 2 *cp2
U = 0.2 kW
m °C
2 10000
FM_07/ 2000
Le concept du pincement thermodynamique
Excédent d'énergie
T(°C)
175°
150°
1er principe thermo :
Bilan de chaleur 100° Echange
70°
impossible
H(kW)
Supplément d'énergie
T(°C)
175°
150°
2ème principe thermo :
100° Potentiel
DT > 0 de transfert
70°
Excédent d'énergie H(kW) nul
FM_07/ 2000
DTmin influence
T
Low DTmin
DT1
Qh1 <<
Qh1
Qc1 <<
Qc1
A >>
Q
T
High DTmin
DT2 Qh2 >>
Qh2
Qc2 >>
Qc2
A <<
Q
FM_07/ 2000
DTmin Influence
(1 + i)n − 1
(cHU ∗ (Q̇c − Q̇hx (∆Tmin )) + ccu ∗ (Q̇h − Q̇hx (∆Tmin ))) ∗ time ∗
i(1 + i)n
Q̇hx (∆Tmin )
+a ∗ ( )b
U ∗ ∆Tlm (∆Tmin )
FM_07/ 2000
Analysing a process
Energy Water - solvents
Raw Products
Processes
materials
by-products
Waste treatment
FM_07/ 2000
Flow sheet
Oxydation
P=4 bar 2NO + O2 -> 2 NO2 Vers traitement
NH3
Conv. Oxy. Abs.
H2O
NO
Air O2
NO2
H2O
P=9 bar
O2
HNO3
• Topology
– Standard representations
• Flux
– Name
– Type process/utility
– Thermodynamic characterisation
• T-P-flows-compositions-enthalpy
– others : viscosity, volume, mol weight, state
– Cost
– Toxicity, Environmental regulation
• Equipments
– Type - principles
– Constructing materials
– Nominal operating conditions
• Spec sheets
Example de P&ID
Source : R.!Turton, W.!Whiting, and J.!Shaeiwitz. Analysis, Synthesis and Design of chemical processes. Prentice Hall, NJ,, 1998.
41°C
104°C
185°C
536°C
45°C
20°C
243°C
Air HNO3
Vers traitement
FM_07/ 2000
Hot and cold streams
Examples
Examples
• Distillation boilers
• Distillation condenser • Reactants Preheating
• Exothermics reactor • Cooling water
• Fumes • Steam production
• Steam condenser • Cold stream of a refrigeration cycle
• Hot stream of a
refrigeration cycle
T T
H
H
FM_07/ 2000
Assumptions : constant Cp ?
Fluid phase changes
2
T
!=1
Potential pinch point if
!=0 4
cold stream
3
1
Add new temperatures in the list :
one stream= several segments
H
T
use linearized segments
FM_07/ 2000
Energy requirement definition
• Mixing
FM_07/ 2000
FM_07/ 2000
Do not forget the system limits
• Streams leaving the system
– minimum target temperatures
– minimum pressure required (expansion ?)
• Waste streams
– energy valorisation possible
– recycle
– emission control
• Raw material preparation
– waste streams ?
FM_07/ 2000
Courbes composées
Intégrale de l’énergie disponible dans les
flux chauds en fonction de la température
Deux flux chauds Courbe composée
T T
CP = A CP = A
CP = A + B
CP = B
CP = B
Q Q
FM_07/ 2000
Composite curves
Analogy with 1 heat exchanger
Hot utility
Heat recovery
T T
CP = A CP = A
DTmin
CP = A + B
CP = B
CP = B
Cold utility
Q Q
FM_07/ 2000
T
Tn+1
FM_07/ 2000
Courbes composées
Energie cédée par les flux
chauds entre Tk+1 et Tk+1
Rk+1 Energie reçue par les flux
T froids entre Tk+1 et Tk
Tn+1
Flux chaudsk Flux froidsk
# m˙ j k cp j k (Tk+1 " Tk ) # m˙ i k cpi k (Tk+1 " Tk )
j k =1 i k =1
Tk Rk
! !
Flux chaudsk Flux froidsk
R = Rk+1 +
0.2 Methodologyk for designing
# m˙ j k utility
integrated
cp j k (Tk+1 " Tk ) "
systems
# m˙ i k cpi k (Tk+1 " Tk ) 5
j k =1 i k =1
Rr ≥ 0 ∀r = 1, ..., nr + 1 (3)
The heat cascade constraints (2) is the equation system that is solved by the problem table
method. An alternative set of equations (4) may be used to compute the heat cascade. FM_07/ 2000This
formulation has the advantage of involving only one Rr per equation, each of the equation
being related to one temperature in the temperature list. From the analysis of the pinch point
location it may be demonstrated that the list of temperatures (and therefore of equations) may
be reduced in this case to the list of inlet temperature conditions of all the streams. By saying
that, we assume that the fluid phase changing streams are divided into streams segments.
where theRhot r andthecold
energy cascadedcurves
composite from the temperature
of the process are interval r to theislower
the closest, tempera-
further used to de-
ture intervals in the time period p;
sign the heat recovery heat exchanger network structure. Using the concept of the hot and
Qir curves,
cold composite the heat itload of the reference
is possible level graphically
to compute of process stream
the MER.i in the temperature the
Mathematically,
minimum energyinterval
requirement 0 for hot streams
r; Qir is>computed by solving ≤ 0heat
and the for cascade
cold streams;
model (1). This model
is a one degree of freedom linear programming problem that computes the the energy required
The heat
to balance thecascade
energyconstraints
required by(2)theis the
coldequation
streamssystem that
with the is streams
hot solved byfor theeach
problem table
temperatures
method. An alternative set of equations (4) may be used to compute the heat cascade. This
Linear programming formulation
of the problem. The Grand composite curve is the plot of this heat requirement as a function
formulation has the advantage of involving only one Rr per equation, each of the equation
of the temperature.
being related to one temperature in the temperature list. From the analysis of the pinch point
locationmin
it may
Rnrbe demonstrated that the list of temperatures (and therefore of equations) may (1)
+1
be reduced
Rr in this case to the list of inlet temperature conditions of all the streams. By saying
that, we assume that the fluid phase changing streams are divided into streams segments.
subject to heat balance of the temperature intervals
nr !
n
!
! n
+i,k
(Qi,r Q R)r+1
+ R−nrR
+1r =
−R0 r =∀r
0 = ∀r
1, ...,
= 1,nr..., nr (4) (2)
k=r i=1
i=1
Rr ≥ 0 ∀r = 1, ..., nr + 1 (3)
The heat cascade constraints (2) is the equation system that is solved by the problem table
method. An alternative set of equations (4) may be used to compute the heat cascade. FM_07/ 2000This
formulation has the advantage of involving only one Rr per equation, each of the equation
being related to one temperature in the temperature list. From the analysis of the pinch point
location it may be demonstrated that the list of temperatures (and therefore of equations) may
be reduced in this case to the list of inlet temperature conditions of all the streams. By saying
that, we assume that the fluid phase changing streams are divided into streams segments.
nr !
! n
( Qi,k ) + Rnr +1 − Rr = 0 ∀r = 1, ..., nr (4)
k=r i=1
The algorithm
FM_07/ 2000
Composite curves analysis
Benefit :
600
Cold composite curve "E=Qh - Qhmin
Hot composite curve
550
Corrected temperatures
Hot utility
500
450
T(K)
Heat recovery
400
350
refrigeration
250
0 5000 10000 15000 20000 25000 30000
Q(kW)
FM_07/ 2000
550
Hot Utility : 6854 kW
Self sufficient
500 "Pocket"
450
T(K)
400
350
FM_07/ 2000
The more in - The more out
Overall heat balance
$ nshot ' $ nscold '
˙ ( ˙ )
&& E in + # ( m˙ i cpi (Tini " Touti )))) " # m˙ j cp j (Tin j " Tout j ) + E out ) = 0
&
& )
% i=1 ( % j=1 (
Therefore :
nshot nscold
! As : # ( m˙ i cpi (Tini " Touti )) " # (m˙ j cp j (Tin j " Tout j )) = Constant
i=1 j=1
$ E˙ in " E˙ out = Constant
and ( E˙ in ) " E˙
today ( out ) today
= Constant
FM_07/ 2000
Important rules
Q1
Q1
+Qf
No cold utility above the pinch point
FM_07/ 2000
Targeting
• Composite curves
– Minimum Energy Requirement : MER
• What about the energy capital trade-off ?
– Cost of Energy
– Cost of investment
– ? "Tmin ?
(Q˙ MER _ HU ("Tmin ) # Q˙ HU ) * CHU Hot utility
+(Q˙ MER _ CU ("Tmin ) # Q˙ CU ) * CCU + (Q˙ MER _ RU ("Tmin ) # Q˙ RU ) * CRU Cold utility
n exchangers
1
+ *
$
% I(Ai ("Tmin )) kCHF /an Investment
i=1
!
FM_07/ 2000
Th,i Tc,i-1
i Tc,i Qi
! Q"
(Qh,c )i 1 1 Qi
Ah,ci = = + ∗
(Uh,c )i ∗ ∆(Tlm )i hi,h hi,c ∆(Tlm )i
(nstreams )i
! " #
Vertical Qi 1
exchange ⇒ Ai = ∗( ∗ )
(∆Tlm )i j=1
hi,j
nverticale xchanges
!
A= Ai
i=1
FM_07/ 2000
Minimum number of units
Hot Stream Stream
utility 1 2 Sources
20 kW 330 kW 180 kW
2 4
210 kW 3 120 kW
1 120 kW 5
20 kW 60 kW
FM_07/ 2000
1 2 3
20 kW 90 kW 240 kW
Stream 3 Stream 4
110 kW 240 kW Sinks
FM_07/ 2000
Minimum number of units : effect of pinch point
Stream 2 Stream 1
90 kW 90 kW Sources
1 2 3
90 kW 30 kW 90 kW
FM_07/ 2000
FM_07/ 2000
Estimating the investments
nbexchangers % % (c (
' A
! # I(Ai ("Tmin )) $ U min,mer * ' a + b'' ** *
• Estimated investment : i=1 & & min,mer ) *)
U
FM_07/ 2000
Influence of DTmin
Q2
Q1
T(°K) DTmin 1
DTmin 2
Q(kW)
DTmin 1 < DTmin 2
FM_07/ 2000
DTmin sensitivity
Change of the number of exchangers
Cost Total T
Energy
Q
Investment
DTmin
FM_07/ 2000
DTmin value
The DTmin is related to the type of fluids
Heat exchange:
Q = U A DTlm
Heat transfer
coefficient Temperature
1/U = 1/Uc +1/Uf difference
DT = DTmin/2,j + DTmin/2,k
FM_07/ 2000
How to handle this situation ?
Consider stream dependent DTmin/2 for calculating
the heat cascade
FM_07/ 2000
DTmin/2,j
9
# 1 &b
6
"Tmin /2 j = K * %% (( 3
$hj ' 1
0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
hj
FM_07/ 2000
Summary of the work method
TARGETING
process simulation and analysis
DTmin optimization
SYNTHESIS
FM_07/ 2000
Goals
Find a heat exchangers network that satisfies:
- MER
- Minimum number of units
- Minimum investment
- Other criteria
- Which hot stream with which cold stream ?
- What is the heat exchanged ?
- What is the structure : serial or //, ...
Qhmin
T(°K)
HEAT
SOURCE
DTmin
DTmin
HEAT
SINK
Qcmin
Q(kW)
FM_07/ 2000
Pinch streams
HEAT
SINK
No cold utility above the pinch point
Q(kW)
FM_07/ 2000
Heat exchanger representation
Pinch
Q(kW) T
The goal is to cool down hot streams to the pinch
temperature without utility
FM_07/ 2000
Feasibility rules
Numbers of streams
80 80 For pinch exchangers
2 90 2 90
Hot Hot
80 streams 80 streams
3 140 3 140 Above the pinch point:
Number of hot ! Number of cold
?
80 Cold Below the pinch point:
1 135 Cold 1 135 stream Number of cold " Number of hot
stream 80
Pinch Pinch
ṁcp k ≤ ṁcpr
T
CPh CPhSCPc
1
DTmin ṁcpr
CPc
1 CPc
Pinch
Q
Direction de calcul
For the exchange between hot stream {k} and cold stream {r} above the pinch point
ṁcpk ≤ ṁcpr
for pinch exchangers:
n
! n!
and
hot cold
Above the pinch point:
ṁcpk ≤ ṁcpj
Cp hot " Cp cold
i=1,i!=k j=1,j!=r
Below the pinch point:
Cp cold " Cp hot
True globaly
FM_07/ 2000
Au dessus du pincement
˙ k cpk = 2
m Split du flux clé si la
règle des cp n’est pas
˙ rcp r = 1
m satisfaite
Direction de calcul
˙ 2,k cp 2,k = 2 " m˙ 1,kcp1,k
m
Q˙
Q˙ T = Tpinch + "Tmin +
m˙ 1,k cp1,k
˙ 1,k cp1,k " 1
m
Q˙
T = Tpinch " #Tmin +
Q˙ m˙ r cpr
!
˙ rcp!r = 1
m
Règle heuristique : Calcul
!
du taux de split pour mélange isotherme
! FM_07/ 2000
Heuristic rules
Goals :
Above the pinch point: cool down the hot streams without cold utilities.
Below the pinch point : heat up the cold streams without hot utilities.
FM_07/ 2000
Toc Tic
T1 T2
Remaining problem T4 T3
Tif Tof
Hot streams:
Tic -> T2
T1 -> Toc =>MER1
Cold streams:
Tif -> T4 if MER1=MER0 =>OK
T3 -> Tof
FM_07/ 2000
The synthesis algorithm
N k " N k #1
yes no
m
˙ k cpk " m˙ k #1cp k #1 Split {k-1} stream
nk n k#1
et %
i =1,i $k
m˙ icpi " %
j =1, j $ k #1
m˙ j cp j
no
yes All examined Split 1 {k} stream
no
accept suppress Key streams :
yes
New data set Above the pinch point : hot streams
Below the pinch point : cold streams
FM_07/ 2000
HEN synthesis
FM_07/ 2000
Heat load distribution
T*k+1 Qjk
Qikj
Qikj Qjk
Qik Qikj Qjk
T*k
"Q j =1
ikj = Qik #i = 1,...,nh;#k = k1,...,k2
Cold stream j in and above temperature interval k
nh k2 k2
"Q
r =k
irj # y ijQmax ij $ 0 %j = 1,...,nc;%i = 1,...,nh
FM_07/ 2000
nh nc
Min " " y ij yij " {0,1}
yij ,Qikj
i =1 j =1
nc
nh k2 ! k2
""
i=1 r= k
Qirj $ " Q jr % 0
r= k
#j = 1,...,nc;#k = k1,...,k2
k2
"Q
r =k
irj $ y ijQmax ij % 0 #j = 1,...,nc;#i = 1,...,nh
FM_07/ 2000
Multiple solutions
• Add heuristic rules
– favour the connexion with utility streams
– favour close connexions
– favour connexion in closer sub-systems
• A heuristic rule is applied only if it does not
penalize the minimum number of solution
target
FM_07/ 2000
FM_07/ 2000
Improving the speed of convergence
Iter= 0
r= 1
MILP problem
iter=iter+1
solution ? no
yes
solution ?
yes
no
END
FM_07/ 2000
P roblemk +
FM_07/ 2000
The synthesis method
FM_07/ 2000
NLP problem
nu
1 nex
Min
X ,m j ,A i
" (C1 j + C2 j m˙ j ) + " ( ai + bi Aici )
# i =1 T1o L L-V V T1i
j =1
Constraints L L L
T2i T2o
Heat and mass balances V
T1i
L-V
Rating equations T1o
L
A2
A3
T2o
Specifications : A1
T2i L L L
F(X) = 0
Bounds and limits nz i nzi
n Qi Qiz
Ai =A="?nAAi = ?"
z,i =
z =1i=1 i=1 U iz#Tlmiz
z =1UDTlmi
G(X) " 0
FM_07/ 2000
Heat exchanger network superstructure
ṁ7 , y7 , T7
y3 ṁmin ≤ ṁ3 ≤ y3 ṁmin E
ṁ3 , y3 , T3 2 ṁ9 , y9 , T9
ṁ10 , y10 , T10
E
2
E
1
FM_07/ 2000
MINLP problem
nu
! nhx
1!
min (yu C1u + Ṁu cu ) + (ah yh + bh (Ah )ch )
Ah ,yh ,Ṁi ,yj
u=1
τ
h=1
st.
F (A, y, Ṁ , T ) = 0
G(A, y, Ṁ , T ) = 0
Amin
h yh ≤ Ah ≤ Amax h yh ∀h = 1 . . . nhx
Ṁimin yi ≤ Ṁi ≤ Ṁimax yi ∀i = 1 . . . ns
FM_07/ 2000
MINLP sub-problem
• HRAT : Heat recovery approach temperature
– target
• EMAT : exchanger Minimum Approach Temperature
nu
! nhx
1!
min (yu C1u + Ṁu cu ) + (ah yh + bh (Ah )ch )
Ah ,yh ,Ṁi ,yj
u=1
τ
h=1
st.
F (A, y, Ṁ , T ) = 0
G(A, y, Ṁ , T ) = 0
∆Ti,hx ≥ EM AT ∀i = 1, 2 hx = 1, . . . , nhx
Ṁu = Ṁu,target ∀u = 1 . . . nu
Amin
h yh ≤ Ah ≤ Amax
h yh ∀h = 1 . . . nhx
min max
Ṁi yi ≤ Ṁi ≤ Ṁi yi ∀i = 1 . . . ns
FM_07/ 2000
FM_07/ 2000
Heat exchanger network retrofit
C1 3
C2 4
2 1
1) Identifier les échangeurs mal placés
H1
C1 3 PINCH
C2 4
2) Déconnexion 2 1
3) Pinch design
4) Récupération des échangeurs 2
4 1 H1
PINCH
FM_07/ 2000
If required A ! A available
=> use a by-pass
=> or accept lower DTmin
FM_07/ 2000
MINLP problem
FM_07/ 2000