Advance HEN Synthesis

Contains Material Developed by Dr. Daniel R. Lewin,

Department of Chemical Engineering ,Technion, Haifa, Israel
Topics
Loops and Splits
Minimum Number of Units by
Loop Breaking
Stream Split Designs
• Threshold Problems
Objectives
Students should be able to:
 Identify and eliminate “heat loops”
in an MER design
 Use stream splits to design for Umin
and MER
 Design a HEN for “Threshold
Problems”
Loops
Pinch

H1 1 2 3 4 C

H 1 3 C1

H 2 4 C2
Loops
Pinch

H1 1 2 3 4 C

H 1 3 C1

H 2 4 C2
Loops
Pinch

H1 1 2 3 4 C

H 1 3 C1

H 2 4 C2
Loops
Pinch

H1 1 2 3 4 C

H 1 3 C1

H 2 4 C2
Loops
Pinch

H1 1 2 3 4 C

H 1 3 C1

H 2 4 C2

Three heat loops in the HEN system

Independent Network
H1 1 C

H2 2 3

1 C1

2 C2

H 3 C2

Two Independent Network

The minimum number of units (Umin) in
a network:
Umin = NStream + NUtility − 1

A HEN containing UHEX units (UHEX > Umin)

has (UHEX − Umin) independent “heat
loops”
H1 1 2 3 C

H 1 3 C1

H 2 C2

The HEN above has 2 “heat loops”

Normally, when heat loops are
“broken”, heat flows across
the pinch - the number of heat
exchangers is reduced, but
the utility loads are increased
Example
CP
Stream TS (oC) TT (oC) DH (kW)
(kW/oC)
H1 180 40 280 2,0
H2 150 40 440 4,0
C1 60 180 360 3,0
C2 30 130 260 2,6

DTmin = 10oC
(Linnhoff and Flower, 1978)
Example
• Step 1: Temperature Intervals
(subtract ΔTmin from hot temperatures)

• Temperature Intervals
180oC  170oC  140oC  130oC ...
... 60oC  30oC
Example
• Step 2: Interval heat balances
(For each interval, compute:
ΔHi = (Ti − Ti+1)×(ΣCPHot −ΣCPCold )
Example
Inter ΣCPHot−
val
H1 H2 C1 C2 Ti Ti+1 ΣCP ΔHi
Cold
1 180 10 -3,0 -30
2 170 30 -1,0 -30
3 140 10 3,0 30
4 130 70 0,4 28
5 60 30 3,4 102
6 30
 QH QH = 0 QH = 60
Example T1 = 180oC

DH = - 30
Q1 Q1 = -30 Q1 = 30
• Step 3: T2 = 170oC

DH = - 30
Form
Q2 Q2 = -60 Q2 = 0
enthalpy T3 = 140oC

cascade. DH = 30
Q3 Q3 = -30 Q3 = 30
T4 = 130oC

DH = 28
This defines: Q4 Q4 = -2 Q4 = 58
T5 = 60oC
Cold pinch = 140oC
DH = 102
QHmin = 60 kW
QCmin = 160 kW QC QC = 100 QC = 160
T7 = 30oC
Example
• MER Design above the pinch:
180oC 150oC
H1 C CP = 2,0

180oC 160oC 140oC

H C C1 CP = 3,0
60 60
UMin,MER = NStream + NUtility - 1
=2+1–1
=2
Example Tahap 4: Disain cold-end, mulai pada pinch.
Pasangkan penukar panas menurut kendala CP.
(Untuk di bawah pinch, berlaku CPHOT  CPCOLD)

• MER Design below the pinch:

150oC 110oC 40oC
H1 C C CP = 2,0
140oC
150oC 110oC 80oC 40oC
H2 C C C C CP = 4,0
160
140oC 126,67oC 100oC
60oC
C C C C1 CP = 3,0
40 80 120
130oC 30oC
83,85oC
C C C2 CP = 2,6
120 140
Example

UMin,MER = NStream + NUtility - 1

=4+1–1=4
MER design below pinch has 6 exchangers!
i.e. There are two loops below pinch
 Example
Complete MER Design
180oC 150oC 110oC 40oC
H1 C C C CP = 2,0

150oC 140oC 110oC

80oC 60oC
H2 C C C C CP = 4,0
160
180oC 160oC 140oC 126,67oC 100oC
60oC
H C C C C C1 CP = 3,0
60 60 40 80 120
130oC 83,85oC 30oC
C C C2 CP = 2,6
120 140
 Example

However, UMin = NStream + NUtility − 1 = 4 + 2 − 1 = 5

The MER network h as 8 units.
This implies 3 independent “heat load loops”.
We shall now identify and eliminate these loops in order
to design for UMin
 Example
Identification and elimination of 1st loop:
180oC 150oC 110oC 40oC
H1 C C C CP = 2,0

150oC 140oC 110oC

80oC 60oC
H2 C C C C CP = 4,0
160
180oC 160oC 140oC 126,67oC 100oC
60oC
H C C C C C1 CP = 3,0
60 60 40 80 120
130oC 83,85oC 30oC
C C C2 CP = 2,6
120 140
 Example
Identification and elimination of 1st loop:
180oC 150oC 110oC 40oC
H1 C C C CP = 2,0

150oC 140oC 110oC

80oC 60oC
H2 C C C C CP = 4,0
160
180oC 160oC 140oC 126,67oC 100oC
60oC
H C C C C C1 CP = 3,0
60 140
60 40 80 120
130oC 83,85oC 30oC
C C C2 CP = 2,6
120 140
 Example
Identification and elimination of 1st loop:
180oC 110oC 40oC
H1 C C CP = 2,0

150oC 140oC 110oC

80oC 60oC
H2 C C C C CP = 4,0
160
180oC 160oC 113,33oC 100oC
60oC
H C C C C1 CP = 3,0
60 140 40 120
130oC 83,85oC 30oC
C C C2 CP = 2,6
120 140
Example ΔTmin volation
180oC 110oC 40oC
H1 C C CP = 2,0

150oC 140oC 110oC

80oC 60oC
H2 C C C C CP =
160 4,0
180oC 160oC 113,33oC 100oC
60oC
H C C C C1 CP =
60 140 40 120 3,0
130oC 83,85oC 30oC
C C C2 CP =
120 140 2,6
To reduce the number of units, the 80 kW exchanger is
merged with the 60 kW exchanger. This breaks the heat
loop, but also creates a ΔTmin volation in the network.
Example ΔTmin volation
180oC 110oC 40oC
H1 C C CP = 2,0

150oC 140oC 110oC

80oC 60oC
H C C C C CP =
4,0
2 160
180oC 160oC 113,33oC 100oC
60oC
H C C C C1 CP =
60 140 40 120 3,0
130oC 83,85oC 30oC
C C C2 CP =
120 140 2,6
To restore ΔTmin, the loads of the exchangers must be
adjusted along a “heat path” by an unknown amount x .
A “heat path” is a path through the network that
connects heaters with coolers.
 Example
Identification and elimination of 1st loop:
ΔTmin volation
180oC 110oC 40oC
H1 C C CP = 2,0

150oC 140oC 110oC

80oC 60oC
H2 C C C C CP = 4,0
80
180oC 160oC 113,33oC 100oC
60oC
H C C C C1 CP = 3,0
60 140 40 120
130oC 83,85oC 30oC
C C C2 CP = 2,6
120 140
 Example
Identification and elimination of 1st loop:
ΔTmin volation
180oC 110oC 40oC
H1 C C CP = 2,0

150oC 140oC 110oC

80oC 60oC
H2 C C C C CP = 4,0
80
180oC 160oC 113,33oC 100oC
60oC
H C C C C1 CP = 3,0
60 140 40 120
130oC 83,85oC 30oC
C C C2 CP = 2,6
120 140
 Example
Identification and elimination of 1st loop:
ΔTmin volation
180oC 110oC 40oC
H1 C C CP = 2,0

150oC 140oC 110oC

80oC 60oC
H2 C C C C CP = 4,0
80 + x
180oC 160oC 113,33oC 100oC
60oC
H C C C C1 CP = 3,0
60 + x 140 - x 40 120
130oC 83,85oC 30oC
C C C2 CP = 2,6
120 - x 140 + x
 Example Tmin violation (100 – 113,33) = 13,33oC

Performing a heat balance on H1 in the

exchanger which exhibits the ΔTmin violation:
140 - x = 2(180 - 113.33 - ΔTmin) ⇒ x = 26.66
 Example
Identification and elimination of 1st loop:
ΔTmin volation Corrected
180oC 123,33oC 40oC
H1 C C CP = 2,0

150oC 116,66oC 86,66oC

140oC 60oC
H2 C C C C CP = 4,0

151,1oC 106,64
180oC 113,33oC 100oC
60oC
H C C C C1 CP = 3,0
86,66 113,33 40 120
130oC 94,1oC 30oC
C C C2 CP = 2,6
93,33 166,66

This is called “energy relaxation”

 Example
Identification and elimination of 2nd loop:
180oC 123,33oC 40oC
H1 C C CP = 2,0

150oC 116,66oC 86,66oC

140oC 60oC
H2 C C C C CP = 4,0

151,1oC 106,64
180oC 113,33oC 100oC
60oC
H C C C C1 CP = 3,0
86,66 113,33 40 120
130oC 94,1oC 30oC
C C C2 CP = 2,6
93,33 166,66
 Example
Identification and elimination of 2nd loop:
180oC 123,33oC 40oC
H1 C C CP = 2,0

150oC 126,66oC 86,66oC

60oC
H2 C C C CP = 4,0

151,1oC 106,64
180oC 113,33oC 60oC
H C C C1 CP = 3,0
86,66 113,33 160
130oC 94,1oC 30oC
C C C2 CP = 2,6
93,33 166,66
Example
Identification and elimination of 2nd loop:

Since there is no ΔTmin violation, no adjustment of the

loads of the exchangers is needed - we reduce the
number of units by one with no energy penalty.
 Example
Identification and elimination of 3rd loop:
180oC 123,33oC 40oC
H1 C C CP = 2,0

150oC 126,66oC 86,66oC

60oC
H2 C C C CP = 4,0

151,1oC 186,66
180oC 113,33oC 60oC
H C C C1 CP = 3,0
86,66 113,33 160
130oC 94,1oC 30oC
C C C2 CP = 2,6
93,33 166,66
Example
Identification and elimination of 3rd loop:

Shifting the load of the smallest exchanger (93.33 kW)

around the loop, the network is reduced to…
 Example
Identification and elimination of 3rd loop:
180oC 170oC 40oC
H1 C C CP = 2,0

150oC 86,66oC 60oC

H2 C CP = 4,0

151,1oC 186,66
180oC 144,44oC 60oC
H C C1 CP = 3,0
86,66 20 253,33
130oC 30oC
C C2 CP = 2,6
260
ΔTmin volation = 150 – 144,44 = 5,56 ≤ 10
 Example
Identification and elimination of 3rd loop:
180oC 170oC 40oC
H1 C C CP = 2,0

150oC 86,66oC 60oC

H2 C C CP = 4,0
186,66
180oC 151,1oC 144,44oC 60oC
H C C C1 CP = 3,0
86,66 20 253,33
130oC 30oC
C C2 CP = 2,6
260

Use the heat path to restore ΔTmin

 Example
Identification and elimination of 3rd loop:
180oC 170oC 40oC
H1 C C CP = 2,0

150oC 86,66oC 60oC

H2 C C CP = 4,0
186,66 + x
180oC 151,1oC 144,44oC 60oC
H C C C1 CP = 3,0
86,66 + x 20 253,33 - x
130oC 30oC
C C2 CP = 2,6
260

253.33 - x = 3(150 - ΔTmin- 60) ⇒ x = 13.33

 Example
Therefore Umin Network is: :
180oC 170oC 40oC
H1 C C CP = 2,0

150oC 90oC 60oC

H2 C C CP = 4,0
200
180oC 146,47oC 140oC 60oC
H C C C1 CP = 3,0

100 20 240
130oC 30oC
C C2 CP = 2,6

260
 Loop Breaking - Summary
Step 1:
Perform MER Design for UHEX units.
Try and ensure that design meets
UMin,MER separately above and below
the pinch.
 Loop Breaking - Summary
Step 2:
Compute the minimum number of
units:
UMin = NStream + NUtilIity − 1
This identifies UHEX − Umin
independent “heat loops”, which
can be eliminated to reduce U.
 Loop Breaking - Summary
Step 3:
For each loop, eliminate a unit. If
this causes a ΔTmin violation, identify
the “heat path” and perform
“energy relaxation” by increasing
the duties of the cooler and heater
on the heat path
Class Exercise
Homework due to 13/12-10
 Example
Identification and elimination of 1st loop:
ΔTmin volation
180oC 110oC 40oC
H1 C C CP = 2,0

150oC 140oC 110oC

80oC 60oC
H2 C C C C CP = 4,0
160
180oC 160oC 133,30oC 100oC
60oC
H C C C C1 CP = 3,0
60 140 40 120
130oC 83,85oC 30oC
C C C2 CP = 2,6
120 140