DESIGN OF MAXIMUM ENERGY RECOVERY NETWORKS

MER NETWORKS
Networks featuring minimum utility usage are called MAXIMUM ENERGY RECOVERY (MER) Networks.

DIVISION AT THE PINCH

RECALL THAT No heat is transferred through the pinch. This makes the region above the pinch a HEAT SINK region and the region below the pinch a HEAT SOURCE region.

Heat Sink
Heat is obtained from the heating utility
7.5 1.5 9.0 -6.0 3.0 1.0 4.0 -4.0 0.0 14.0 14.0 -2.0 12.0

Minimum heating utility

Pinch

H
-2.0

Heat Source
Heat is released to cooling utility

10.0

Minimum cooling utility

CONCLUSION
One can analyze the two systems separately, that is, Heat exchangers will not contain heat transfer across the pinch.

PINCH MATCHES
Consider two streams above the pinch
TH,in Tp TC,out= Tp- Tmin + Q/FCpC TH,in= Tp+Q/FCpH But TH,in> TC,out+ Tmin.
Q/FCpH > Q/FCpC

Thus replacing one obtains TC,out

Q

Tp- Tmin

FCpH < FCpC

Golden rule for pinch matches above the pinch.

Tmin

Tmin

Violation when FCpH > FCpC

EXERCISE
A similar rule is obtained below the pinch. Derive it and illustrate it.

ANSWER
Tp TH,out TC,in= Tp- Tmin - Q/FCpC TH,out= Tp-Q/FCpH But TH,out> TC,in + Tmin.

Thus replacing one obtains Tp- Tmin

Q

TC,in

FCpC < FCpH

Golden rule for pinch matches below the pinch.

Tmin

Tmin
Violation when FCpC > FCpH

CONCLUSION
Since matches at the pinch need to satisfy these rules, one should start locating these matches first. Thus, our first design rule:

START BY MAKING PINCH MATCHES

QUESTION
Once a match has been selected how much heat should be exchanged?

ANSWER
As much as possible! This means that one of the streams has its duty satisfied!! THIS IS CALLLED THE

TICK-OFF RULE

HANDS ON EXERCISE
H=27 MW T=140 0C T=230 0C REACTOR 2 T=200 H=32 MW T=20 0C REACTOR 1 T=180
0C 0C

H=-30 MW T=80 0C

H=-31.5 MW T=250 0C T=40 0C

Stream
Reactor 1 feed Reactor 1 product Reactor 2 feed Reactor 1 product Tmin=10 oC

Type
Cold Hot Cold Hot

Supply T
(oC) 20 250 140 200

Target T
(oC) 180 40 230 80

H
(MW) 32.0 -31.5 27.0 -30.0

F*Cp
(MW oC-1) 0.2 0.15 0.3 0.25 PINCH=150 oC

HANDS ON EXERCISE
FCp=0.15 FCp=0.25 H1 H2 180 0C 230 0C 140 0C 250 0C 200 0C 150 0C 40 0C 80 0C

FCp=0.2 FCp=0.3

20 0C

C1 C2

Stream
Reactor 1 feed Reactor 1 product Reactor 2 feed Reactor 1 product Tmin=10 oC

Type
Cold Hot Cold Hot

Supply T
(oC) 20 250 140 200

Target T
(oC) 180 40 230 80

H
(MW) 32.0 -31.5 27.0 -30.0

F*Cp
(MW oC-1) 0.2 0.15 0.3 0.25 PINCH=150 oC

ABOVE THE PINCH

FCp=0.15 FCp=0.25 H1 H2 250 0C 200 0C 150 0C

180 0C FCp=0.2 FCp=0.3 230 0C 140 0C

C1 C2

Which matches are possible?

ANSWER (above the pinch)

FCp=0.15 FCp=0.25 H1 H2 250 0C 200 0C 150 0C

FCp=0.2 FCp=0.3

180 0C C1 230 0C 140 0C C2

The rule is that FCpH < FCpC . We therefore can only make the match H1-C1 and H2-C2.

ANSWER (above the pinch)

FCp=0.15 FCp=0.25 H1 H2 250 0C 200 0C 203.3 0C 150 0C

FCp=0.2 FCp=0.3 230 0C

180 0C 181.7 0C 12.5 C1 8 140 0C C2

The tick-off rule says that a maximum of 8 MW is exchanged in the match H1-C1 and as a result stream C1 reaches its target temperature. Similarly 12.5 MW are exchanged in the other match and the stream H2 reaches the pinch temperature.

BELOW THE PINCH

FCp=0.15 FCp=0.25 H1 H2 150 0C 40 0C 80 0C

FCp=0.2

140 0C

20 0C

C1

Which matches are possible?

The rule is that FCpC < FCpH . Thus, we can only make the match H2-C1

ANSWER (below the pinch)

FCp=0.15 FCp=0.25 H1 H2 150 0C 40 0C

80 0C

FCp=0.2

140 0C 17.5

52.5 0C

20 0C

C1

The tick-off rule says that a maximum of 17.5 MW is exchanged in the match H2-C1 and as a result stream H2 reaches its target temperature.

COMPLETE NETWORK AFTER PINCH MATCHES

FCp=0.15 H1 H2 250 0C 203.3 0C 150 0C 40 0C

FCp=0.25

200 0C

80 0C

FCp=0.2 FCp=0.3 230 0C

180 0C 181.7 0C 12.5 8 140 0C

140 0C 17.5 C2

52.5 0C 20
0C

C1

Streams with unfulfilled targets are colored.

WHAT TO DO NEXT?
FCp=0.15 H1 250 0C 203.3 0C 150 0C 40 0C FCp=0.25 H2 200 0C 80 0C

FCp=0.2 FCp=0.3 230

0C

180 0C 181.7 0C 12.5 8 140 0C

140 0C 17.5 C2

52.5 0C 20 0C

C1

Away from the pinch, there is more flexibility to make matches, so the inequalities do not have to hold. The pinch design method leaves you now on your own!!!!! Therefore, use your judgment as of what matches to select!!

ANSWER
FCp=0.15 H1 250 0C 203.3 0C 150 0C 40 0C FCp=0.25 H2 200 0C 80 0C

FCp=0.2 FCp=0.3 230 0C

180 0C 181.7 0C 12.5 8 140 0C

140 0C 17.5 C2

52.5 0C 20
0C

C1

We first note that we will use heating above the pinch. Thus all hot streams need to reach their inlet temperature. We are then forced to look for a match for H1. Please locate it.

ANSWER
The match is H1-C1. We finally put a heater on the cold stream

FCp=0.15

H1

250 0C

150 0C

40 0C

FCp=0.25

H2

200 0C

80 0C

FCp=0.2 FCp=0.3 230 0C

180 0C 8 H 7.5 7 12.5 140 0C

140 0C 17.5 C2

52.5 0C 20 0C

C1

ANSWER
Below the pinch we try to have the cold streams start at their inlet temperatures and we later locate coolers (one in this case).
FCp=0.15 H1 250 0C 150 0C C 10 FCp=0.25 H2 200
0C

40 0C

80 0C 180 0C 230 0C 8 H 7.5 7 12.5 140 0C 140 0C 17.5 6.5

FCp=0.2 FCp=0.3

20 0C

C1

C2

DISCUSSION
State what are your objections to the pinch design method, so far!!

THESE ARE MINE

It seems to imply building expertise It does not seem to guarantee that one will always obtain a good result. What if there are unequal number of streams at the pinch? What if the inequalities are not satisfied at the pinch?

GENERAL FORMULA FOR UNIT TARGETING

Nmin= (S-P)above pinch+ (S-P)below pinch

If we do not consider two separate problems, above and below the pinch we can get misleading results.

EXAMPLE
FCp=0.15 H1 250 0C 150 0C C 10 FCp=0.25 H2 200 0C 80 0C 180 0C 230 0C 8 H 7.5 7 12.5 140
0C

40 0C

FCp=0.2 FCp=0.3

140 0C 17.5 6.5

20 0C

C1

C2

Nmin= (S-P)above pinch+ (S-P)below pinch = =(5-1) + (4-1) = If we do not consider two separate problems Nmin= (6-1)= 5, which is wrong

Note: A heat exchanger network with 5 exchangers exists, but it is impractical and costly. This is beyond the scope of this course.

UNEQUAL NUMBER OF STREAMS AT THE PINCH

Above the pinch, we notice the following rule SH SC

UNEQUAL NUMBER OF STREAMS AT THE PINCH

Indeed, if the number of hot streams is larger than the number of cold streams, then no pinch matches are possible.
FCp=0.15 FCp=0.25 FCp=0.1 H1 H2 H3 FCp=0.2 FCp=0.4 150 OC 140 OC 130 OC 100 OC

Target=170 OC Target=140 OC

127.5 OC 122.5
OC

90 OC C1 7.5 10 C2

Assume the matches H1-C1 and the matches H2-C2 have been selected. Since H3 needs to go to the pinch temperature, there is no cold stream left to match, even if there is portions of C1 or C2 that are left for matching. Such matching would be infeasible.

What is then, the solution?

ANSWER
Split cold stream until the inequality is satisfied.
FCp=0.15 FCp=0.25 FCp=0.1 H1 H2 H3 150 OC 140 OC 130 OC 100 OC

Target=170 OC Target=140 OC

FCp=0.2 FCp=0.25 FCp=0.15

127.5 OC 130 OC 110 OC 10 3 7.5

90 OC

C1 C2

Notice that different combinations of flowrates in the split satisfy the inequality.

UNEQUAL NUMBER OF STREAMS AT THE PINCH

A similar rule can be discussed below the pinch, that is, SH SC and similar splitting of hot streams may be necessary.

INEQUALITY NOT SATISFIED

Consider the following case:
FCp=0.5 H1 150 OC 100 OC

Target=170

OC

FCp=0.2 FCp=0.4

90 OC C1 C2

Target=140 OC

Suggest a solution.

ANSWER
Split the hot stream
FCp=0.2 FCp=0.3 H1 150 OC 100 OC

Target=170 OC Target=140 OC

FCp=0.2 FCp=0.4

140 OC 127.5 OC 15 10

90 OC

C1 C2

SOLVE THE FOLLOWING PROBLEM

Below the Pinch :
FCp=0.5 FCp=0.3 H1 H2 100 OC Target=40 OC Target=20 OC

FCp=0.7

90 OC

30 OC

C1

ANSWER
Below the Pinch :
FCp=0.5 FCp=0.3 H1 H2 100 OC 40 OC Target=40 OC Target=20 OC

60

OC

FCp=0.5 FCp=0.2

90 OC 30 12

30 OC

C1

COMPLETE PROCEDURE
ABOVE THE PINCH
Start

Yes

FCpHFCpC
at pinch?

Yes

SH SC No Split Cold Stream

No

Place matches

Split Hot Stream

COMPLETE PROCEDURE
BELOW THE PINCH
Start

Yes

FCpH FCpC
at pinch?

Yes

SH SC No Split Hot Stream

No

Place matches

Split Cold Stream

HANDS ON EXERCISE
Type Hot Hot Cold Cold Supply T (oC) 750 550 300 200 Target T (oC) 350 250 900 550 F*Cp (MW oC-1) 0.045 0.04 0.043 0.02

Tmin=50 oC Minimum Heating Utility= 9.2 MW Minimum Cooling Utility= 6.4 MW

ANSWER
FCp=0.04 750 0C FCp=0.045 H1 0.4 FCp=0.04 H2 686.05 0C FCp=0.043 FCp=0.02 900
0C

550 0C 358.89 0C 350 0C

250 0C

400 0C

6 300 0C

C1 C2

550 0C

9.2 1

8 500 0C 6

8.6 200 0C

ANSWER
We are minimizing the number of matches. We saw already that different answers can be obtained if separate regions are not considered.