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N.D. Chaturvedi, S. Bandyopadhyay / Applied Thermal Engineering 62 (2014) 229e238 Table 7 Modied PTA for cyclic batch process. Temp. ( C) 160 155 145 140 137.22 80 60 50 30 25 20 Total MCpDt Net MCpDt Net enthalpy Casc. heat Revised (kWh/ C) (kWh/ C) (kWh) duty (kWh) cascade (kWh) 1.2 0.4 0.1 0.6 1.8 0.7 0.8 0.4 1.2 0.1 0.3 1.2 0.8 0.9 1.5 0.3 0.4 0.4 0.8 0.4 0.3 0 0 6 8 4.5 4.17 17.17 8 4 16 2 1.5 0 6 14 18.5 22.67 5.5 13.5 9.5 6.5 4.5 3 6.5 12.5 20.5 25 29.17 12 20 16 0 2 3.5

Fig. 3. Generation of MGCC of second time interval of Example 1.

Table 8 Stream data for Example 2. Stream name C1 H1 C2 H2 Supply temp. ( C) 80 170 20 150 Target temp. ( C) 140 60 135 30 MCP (kW/ C) 8 4 10 3 Start time (h) 0 0.25 0.5 0.3 End time (h) 0.5 1 0.7 0.8

intervals are extracted after eliminating pockets and these segments are listed in Table 5. Similarly, GCC for the second time interval is generated. The GCC is shifted as per step 3 to create MGCC (Fig. 3). The TGCC of second interval is generated combining pseudo hot streams from rst interval (Table 5) and pseudo hot and cold streams of MGCC of second interval using modied PTA (Table 6). The hot utility requirement is calculated to be 18 kWh. In the last interval, there is only one hot stream so there is no hot utility requirement in this interval hence,
Table 6 TGCC generation for second interval (using modied PTA). Temp. ( C) 160 155 140 137.22 80 60 50 30 20 Total MCpDt (kWh/ C) 1.2 0.4 0.6 1.8 0.7 0.8 0.4 1.2 0.3 Net MCpDt (kWh/ C) 1.2 0.8 1.4 0.4 0.3 0.5 0.9 0.3 0 Net enthalpy (kWh) 0 6 12 3.89 22.89 6 5 18 3 Cascaded heat duty (kWh) 0 6 18 21.89 1 5 0 18 15 Revised cascade (kWh) 18 24 36 39.89 17 23 18 0 3

total hot utility requirement is 18 kWh. The cold utility requirement can be determined using equation (5) as 15 kWh. A reduction of 61.7% and 65.9% can be noted in comparison of TSM [23] results. One of the possible networks to achieve these targets is shown in Fig. 4 (heat exchangers with dotted line indicate heat exchange through intermediate uid). HEN is designed on the basis of pinch design method [55], applied on each interval. Minimum hot and cold utility requirements for cyclic batch process are calculated to be 6.5 kWh and 3.5 kWh, respectively. These results are obtained considering all the individual segments of MGCCs of all time intervals collectively (Table 7) as pseudo streams with zero minimum approach temperature. If heat transfer is considered direct, between different time intervals then shifting of GCC in step 3 to create MGCC is bypassed and the same algorithm is followed. In this case, the hot utility and cold utility requirements for a single batch process are calculated to be 15 kWh and 12 kWh, respectively. For cyclic batch process

125 C Numbers in bold italic are Net MCp (kWh/C)

Numbers in boxes are heat duty (kWh)

18

C1
30 14

0.97 0.83

H1
0.5

88

C2 H2

0.3

3 12 15 18 72

H3

0.0

0.1

0.3

0.4

Fig. 4. Feasible heat exchanger network for Example 1 (heat exchangers with dotted line indicate heat exchange through intermediate uid).

N.D. Chaturvedi, S. Bandyopadhyay / Applied Thermal Engineering 62 (2014) 229e238 Table 9 Interval data for Example 2. I1 (0e.25 h) TS ( C) C1 85 TT ( C) 145 MCpDt (kWh/ C) 2 C1 H1 I2 (0.25e0.3 h) TS ( C) 85 165 TT ( C) 145 55 MCpDt (kWh/ C) 0.4 0.2 C1 H1 H2 I3 (0.3e0.5 h) TS ( C) 85 165 145 TT ( C) 145 55 25

235

MCpDt (kWh/ C) 1.6 0.8 0.6

I4 (0.5e0.7 h) TS ( C) C2 H1 H2 25 165 145 TT ( C) 140 55 25 MCpDt (kWh/ C) 2 0.8 0.6

I5 (0.7e0.8 h) TS ( C) H2 H1 145 165 TT ( C) 25 55 MCpDt (kWh/ C) 0.3 0.4

I6 (0.8e1.0 h) TS ( C) H1 165 TT ( C) 55 MCpDt (kWh/ C) 0.8

Table 10 Interval wise hot utility for TGCCs (Example 2). Time interval Hot utility (kWh) Hot utility (without intermediate uid) (kWh) I1 120 120 I2 8 8 I3 0 0 I4 12 6 I5 0 0 I6 0 0 Total 140 134

targets for hot utility and cold utility are calculated to be 3 kWh and 0 kWh, respectively. 4.2. Example 2: heat exchanger network 2 The stream data for the example [25] are given in Table 8. Two hot and two cold streams of this example can be categorized into six time intervals (shown in Table 9 with shifted temperatures). The minimum allowable temperature difference for heat exchange is given to be 10  C. Applying the proposed algorithm TGCC of each interval is generated and minimum hot utility requirement of each TGCC is calculated (Table 10). The overall cold utility is calculated using equation (5). For single batch, hot and cold utility requirements are calculated to be 140 kWh and 180 kWh, respectively. Fig. 5 shows one of the possible networks (designed on basis of pinch design

method [55]) to achieve these targets. If direct transfer is considered between different intervals then hot and cold utility requirements are calculated to be 134 kWh and 174 kWh, respectively. It may be noted that Kemp and Deakin [25] have proposed the methodology considering direct heat transfer within different intervals. In this case the results obtained via proposed algorithm match with Kemp and Deakin [25]. However, in case of indirect heat integration, the utility targets reported by Kemp and Deakin [25] are infeasible as the constraints of indirect heat transfer between intervals were not imposed. For cyclic batch process, hot and cold utility requirements are calculated to be 35 kWh and 75 kWh, respectively. The targets are calculated to be 20 kWh and 60 kWh for hot and cold utility requirements, respectively for direct heat integration for the cyclic process. These results are identical with those reported by Kemp and Deakin [25]. 4.3. Example 3: two product batch plant The proposed methodology is applied to calculate utility requirement for the two product batch plant that was rst studied by Kondili et al. [56] (corresponding ow sheet represented in Fig. 6). The heating and cooling requirements are incorporated in the example. The production recipe is as follows:

Numbers in boxes are heat duty (kWh)

60

88

H1
28 6 72 44 88

H2
30 120 8
1 0.6

36

C1
16

36

1.06

12

C2 0.0 0.25
0.3 0.5
Numbers in bold italic are Net MCp (kWh/C)

0.94

129 C

0.7

0.8

1.0

Fig. 5. One of the possible HENs for Example 2 (heat exchangers with dotted line indicate heat exchange through intermediate uid).

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N.D. Chaturvedi, S. Bandyopadhyay / Applied Thermal Engineering 62 (2014) 229e238

Fig. 6. Flow sheet corresponding to two product batch plant (Example 3).

Feed A is heated inside a heater (HR). A mixture of 50% feed B and 50% feed C, on a mass basis, is reacted (reaction 1). The product of this reaction is intermediate BC. A mixture of 40% hot A and 60% intermediate BC is reacted (reaction 2) to form product 1 (40%) and intermediate AB (60%). A mixture of 20% feed C and 80% intermediate AB is reacted (reaction 3). The reaction produces impure E. Impure E is puried to produce product 2 (90%) and intermediate AB (10%). A heater (HR) is used to heat feed A. Two reactors, RR1 and RR2 are available to perform three different chemical reactions, reaction 1, reaction 2 and reaction 3 and separator exists to purify impure E. Table 1 shows information regarding the production process. The processing time of each task varies with the batch size. One of the possible schedules (Majozi and Zhu [57]) for 8 h time of horizon to maximize production is shown in Fig. 7. Total production (product 1 and product 2) is 151.3 units comprising 70.9 units of product 1 and 80.4 units of product 2. Feed A is fed to heater, and feed B and feed C are fed to RR1 and RR2 at starting point of horizon. The feed are processed as per recipe, product 1 is produced

via reaction 2, and product 2 is produced after separation. The heating and cooling requirements are listed in Table 11. The minimum temperature difference is taken to be 10  C. The start and end time of streams are extracted (Fig. 7) from the given schedule [57] shown in Table 12 with shifted temperatures. The minimum hot/

Table 11 Data pertaining to energy requirements for Example 3. Task (i) Heating (H) Reaction 1 (R1) Reaction 2 (R2) Reaction 3 (R3) Separation (S) Tin ( C) 50 100 70 100 130 Tout ( C) 70 70 100 130 55 Unit (j) HR RR1 RR2 RR1 RR2 RR1 RR2 SR Cp (kJ/kg  C) 2.5 3.5 3.5 3.2 3.2 2.6 2.6 2.8

Fig. 7. Given schedule and its division into time intervals for Example 3.

N.D. Chaturvedi, S. Bandyopadhyay / Applied Thermal Engineering 62 (2014) 229e238 Table 12 Energy requirement for streams for given schedule (Example 3). Task Unit Start End Temperature ( C) time time Supply Target 2(h) (h) HR RR1 RR2 RR1 RR2 RR1 RR2 RR1 RR2 SR 0.00 0.00 0.00 2.09 2.61 4.75 5.08 6.07 6.07 6.07 1.13 2.09 2.61 4.75 5.08 6.07 6.07 8.00 8.00 8.00 55 95 95 75 75 105 105 75 75 125 75 65 65 105 105 135 135 105 105 50 Mass ow (kg) 70.90 28.99 77.42 50.00 69.16 50.00 39.37 22.34 35.74 89.37 Cp MCp (kJ/kg  C) (kJ/ C) 2.50 3.50 3.50 3.20 3.20 2.60 2.60 3.2 3.2 2.80 177.25 101.47 270.97 160.00 221.31 130.00 102.36 71.488 114.368 250.24

237

neglected then targets are calculated to be 12.75 MJ and 15.18 MJ for hot and cold utility respectively. In this case, cyclic batch, targets are calculated to be 8.63 MJ and 11.06 MJ for hot and cold utility respectively, when role of intermediate uid is not considered targets are 5.13 MJ and 7.56 MJ for hot and cold utility respectively. 5. Conclusion A methodology is proposed to target the hot and cold utility requirements for a batch process prior to detailed design of HEN. The proposed methodology can be applied for calculating targets for both direct and indirect heat transfers between different time intervals by introducing the concepts of MGCC and TGCC. Rigorous mathematical arguments prove the optimality of the proposed algorithm. It is proved that for a single batch process, the total hot utility requirement is the sum of individual hot utility requirement of TGCCs. On the other hand, for a cyclic batch process all the hot and cold segments of MGCCs can be considered together to target the minimum utility requirements. The proposed methodology is based on the concepts of pinch analysis and thereby, provides physical insight to understand thermal integration of batch processes, as illustrated through examples. It should be noted that the proposed methodology sets the thermodynamic minimum targets based on thermodynamic constraints. However, during detailed design activities, it may be possible that the entire thermal integration scope are not exploited due to various practical issues, such as restricted matches, transient effects, topological constraints, constraints related to land area available, etc. Current research is directed toward such issues. Additionally, issues related to the

Heating Rxn 1 Rxn 1 Rxn 2 Rxn 2 Rxn 3 Rxn 3 Rxn 2 Rxn 2 Separation

cold utility requirement can be calculated using proposed algorithm. The total time horizon can be divided into seven intervals (Fig. 7). The targets calculated without integration between these intervals (TSM) are 17.48 MJ and 19.91 MJ for hot and cold utility respectively. Applying the proposed methodology hot utility and cold utility requirements are calculated to be 14.2 MJ and 16.63 MJ. One of the possible networks to achieve this target is shown in Fig. 8 (dotted line indicates heat transfer through intermediate uid). To design HEN pinch design method [55] is used. A reduction of 18.7% and 16.4% can be observed in hot and cold utility (in comparison of TSM [23]) respectively. For cyclic batch, targets are calculated to be 8.63 MJ and 11.06 MJ for hot and cold utility respectively. If role of intermediate uid is

Units

Numbers in boxes are heat duty (MJ)

13.2

Separation

RR2(Rxn 3) 4.63 RR2(Rxn 2) 1.67 RR2(Rxn 1) 2 3.07

3.43

RR1(Rxn 3) RR1(Rxn 2) 0.92 RR1 (Rxn 1) 1.76 Heater 3.54 1.135 2.611 1.28

2.6 3.9

2.14

2.097

4.75 Time (h)

5.085

6.077

Fig. 8. Possible HEN for Example 3 (heat exchangers with dotted line indicate heat exchange through intermediate uid; numbers in boxes are heat duty in MJ).

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