Smith: Chemical Process Design and Integration (Chapters 16,18)

Kemp: Pinch Analysis and Process Integration (Chapter 9)

Process Integration
for Ecient Use of Energy
Cheng-Liang Chen
PSE
LABORATORY
Department of Chemical Engineering
National TAIWAN University
Chen CL 1
Outline
Systematic Approach for Chemical Process Design
How do we go about the design of a chemical process?
What Is Process Integration?
Onion model for process integration
Pinch Analysis: Targeting Heat Recovery in Processes
The Pinch Design Method for Heat Recovery Systems
A Pinch Study Performed on A Major Operating Plant
Utility Selection for Individual Processes
Putting It into Practice
Concluding Remarks
Chen CL 2
Heat Exchanger Network Design:
The Pinch Design Method
Chen CL 3
Design of Individual Processes
for Maximum Energy Recovery
Divide the process at the pinch
Chen CL 4
Design of Individual Processes
for Maximum Energy Recovery
The feasibility of heat transfer
Chen CL 5
Design of Individual Processes
for Maximum Energy Recovery
Cross-pinch heat transfer: Actual = Target + XP
Chen CL 6
Design of Individual Processes
for Maximum Energy Recovery
Cold utility above the pinch Hot utility below the pinch
Chen CL 7
Design of Individual Processes
for Maximum Energy Recovery
Design Rule
Do Not Transfer Heat Across the Pinch
Do not use steam below
Do not use cooling water above
Do not recover process heat across
Chen CL 8
Typical Grid Diagram
Chen CL 9
Typical Grid Diagram
Rules for Construction
Hot streams run left to right
Cold streams run right to left
Hot streams on top; Cold streams on bottom
Hot utility =

H
Cold utility =

C
Heat exchanger between streams =

Chen CL 10
Where Is The Pinch ?
Chen CL 11
Pinch Is Easily Shown
Chen CL 12
Separate Above/Below-Pinch Regions
Chen CL 13
Number of Heat Exchanger Units
Graph any collection of points in which some pairs of points are
connected by lines
Path a sequence of distinct lines which are connected to each
other
Chen CL 14
Number of Heat Exchanger Units
A graph forms a single component if any two points are joined by
a path
Loop a path which begins and ends at the same point (CGDHC)
If two loops have a line in common, they can be linked to form
a third loop by deleting the common line (BGCEB + CGDHC
BGDHCEB)
The number of independent loops for a graph:
N
UNITS
= S +L C
N
UNITS
= # of matches or units (lines in graph theory)
S = # of streams including utilities (points in a graph)
L = # of independent loops
C = # of components
A single component and loop-free: N
UNITS
= S 1
Chen CL 15
Number of Heat Exchanger Units
If the problem has a pinch:
N
UNITS
= (S
above pinch
1) (S
below pinch
1)
To target the number of units for pinched problems, the streams
above and below the pinch must be counted separately
(N
UNITS
= (5 1) + (4 1) = 7)
Chen CL 16
The Pinch Design Method
Stream Type Supply Temp. Target Temp. H Heat Capacity Rate
T
S
(
o
C) T
T
(
o
C) (MW) mC
p
(MW/
o
C)
1. Reactor 1 feed Cold 20 180 +32.0 0.20
2. Reactor 1 prod Hot 250 40 31.5 0.15
3. Reactor 2 feed Cold 140 230 +27.0 0.30
4. Reactor 2 prod Hot 200 80 30.0 0.25
Chen CL 17
The Pinch Design Method
Known
No exchanger should have a temp di. smaller than T
min
No heat transfer across the pinch by
process-to-process heat transfer
inappropriate use of utilities
Composite
curves:
Chen CL 18
The Pinch Design Method
Start at the Pinch
(T
min
exists between all hot/cold streams, the most constrained region)
Chen CL 19
The Pinch Design Method
Divide at the pinch
Chen CL 20
The Pinch Design Method
CP Inequality for Individual Matches
Above Pinch: if CP
H
>CP
C
infeasible!
T
h
= 162
o
(suppose)
H
h
= 0.25(162150)
= 3 MW
T
c
= 140 +
3 MW
0.2 MW/
o
C
= 155
o
C
T
min
> T
h
T
c
= 162 155
= 7
o
C
Chen CL 21
The Pinch Design Method
CP Inequality for Individual Matches
Above Pinch: if CP
H
CP
C
feasible
T
h
= 162
o
(suppose)
H
h
= 0.25(162150)
= 3 MW
T
c
= 140 +
3 MW
0.3 MW/
o
C
= 150
o
C
T
min
< T
h
T
c
= 162 150
= 12
o
C
Chen CL 22
The Pinch Design Method
CP Inequality for Individual Matches
Below Pinch: if CP
H
<CP
C
infeasible!
T
c
= 125
o
(suppose)
H
c
= 0.2(140120)
= 3 MW
T
h
= 150
3 MW
.15 MW/
o
C
= 130
o
C
T
min
> T
h
T
c
= 130 125
= 5
o
C
Chen CL 23
The Pinch Design Method
CP Inequality for Individual Matches
Below Pinch: if CP
H
CP
C
feasible
T
c
= 125
o
(suppose)
H
c
= 0.2(140120)
= 3 MW
T
h
= 150
3 MW
.25 MW/
o
C
= 138
o
C
T
min
< T
h
T
c
= 138 125
= 13
o
C
Chen CL 24
The Pinch Design Method
CP Inequalities: Summary
for temperature dierences to increase moving away from the pinch
Above Pinch: CP
H
CP
C
Below Pinch: CP
H
CP
C
Chen CL 25
The Pinch Design Method
The CP Table
Cold utility must not be used above the pinch
hot streams must be cooled to pinch temp. by recovery
hot utility can be used on cold streams above the pinch
Chen CL 26
The Pinch Design Method
The Tick-O Heuristic (above pinch)
Now we have identied feasible matches
How big should we make them ?
Chen CL 27
The Pinch Design Method
The Tick-O Heuristic (above pinch)
Maximize loads to tick o streams
to keep capital costs down
Chen CL 28
The Pinch Design Method
The Tick-O Heuristic (above pinch)
Then ll in the rest
Chen CL 29
The Pinch Design Method
The Tick-O Heuristic (above pinch)
Then ll in the rest
Chen CL 30
The Pinch Design Method
The Tick-O Heuristic (below pinch)
Maximize loads to tick o streams
to keep capital costs down
Chen CL 31
The Pinch Design Method
The Tick-O Heuristic (below pinch)
Maximize loads to tick o streams
to keep capital costs down
Chen CL 32
The Pinch Design Method
The Tick-O Heuristic (below pinch)
Then ll in the rest
Chen CL 33
The Pinch Design Method
The Tick-O Heuristic (below pinch)
Then ll in the rest
Chen CL 34
The Pinch Design Method
The Tick-O Heuristic (below pinch)
Note: one match violates CP rules
But, it is away from the pinch and therefore feasible
Chen CL 35
The Pinch Design Method
The Tick-O Heuristic: Summary
To tick o a stream, individual units are made as large as possible
the smaller of the two heat duties on the streams being matched
Chen CL 36
The Pinch Design Method
The Completed Design
Chen CL 37
The Pinch Design Method: Summary
Divide the problem at the pinch into separate problems
Design separate problems, started at the pinch, moving away
Temperature feasibility requires constraints on CP values to be
satised for matches between streams at the pinch
Loads on individual units are determined using the kick-o heuristic
to minimize # of units
Away from the pinch: more freedom, use judgment and process
knowledge
Chen CL 38
Stream Splitting: # of Streams
Cold utility must not be used
above the pinch
All hot streams must be cooled to
pinch temperature by heat recovery
Splitting cold streams
Above Pinch: S
H
S
C
Chen CL 39
Stream Splitting: # of Streams
Hot utility must not be used
below the pinch
All cold streams must be heated to
pinch temperature by heat recovery
Splitting hot streams
Below Pinch: S
H
S
C
Chen CL 40
Stream Splitting: CP Inequality
Above Pinch: CP
H
CP
C
Hot stream with larger CP values
Split into smaller parallel
hot streams
(opt ow rates ?)
Chen CL 41
Stream Splitting: CP Inequality
Below Pinch: CP
H
CP
C
Cold stream with larger CP values
Split into smaller parallel
cold streams
(opt ow rates ?)
Chen CL 42
Stream-Splitting Algorithms
Above the Pinch
Chen CL 43
Stream-Splitting Algorithms
Below the Pinch
Chen CL 44
Design of Individual Processes
for Maximum Energy Recovery
Pinch Design Rule
Do Not Transfer Heat Across the Pinch
Divide at the PINCH
Start at the PINCH and move away
Observe the PINCH rules:
Do not use steam below
Do not use cooling water above
Do not recover process heat across
Chen CL 45
Thank You for Your Attention
Questions Are Welcome