Result and Discussion

HEN-1

There are a total of 23 heat exchangers within the refinery complex and the heat
exchangers are sectioned into 3 Heat Exchange Networks. One of the sections is shown in
Figure 1 named HEN-1.

Figure 1: PFD of HEN-1

In Table 1, result analysis of HEN-1 is extracted and tabulated where the process
heating and cooling duties are identified.

Table 1: Problem Table for HEN-1

 Figure 2 shows the enthalpy-temperature curves of both hot stream and cold

stream. Since enthalpy is a relative value, the first point (T=60C) can be assumed to be

zero. The right end of the composite curves of the hot and cold streams have the same

enthalpy. This indicates that there is proper stream matching, and adequate and efficient

process to process heat integration and utilisation. Hence, there is no excess heating

requirement (hot utility) for the cold stream. Meanwhile, the left end of the curve shows a

slight excess of cooling requirement (cold utility) in the hot stream that is not utilised fully.

Pinch location divides the process into two separate systems which means that the

areas below and above the pinch location should be designed separately, when designing the

process network. Due to the fact that heat can only supplied above the pinch point

temperature, the pinch location cuts across the end points of the cold and hot streams

composite curves. This is because there should be no external hot utility (heater) in HEN-1

hence, this point gives minimum heat transfer.

There is a heat imbalance due to the little excess cold utility in the hot stream as a

hot utility is absent in the cold stream to match it.

 Figure 2: Composite Curve of HEN-1

The Grand Composite Curve is one of the basis of Cascade diagram. The grand

composite curve is a graphical representation of the excess heat available to a process

within each temperature interval. In Figure 3, the right side of the dotted pinch line

indicates the amount of heat energy efficiently utilised by the cold and hot streams, whereas

the area to the left shows the unutilised excess heat in HEN-1.

The pinch analysis targeting report shows that HEN-1 requires a minimum of cold utility of

2421kW and a minimum of hot utility of 0kW.

 Figure 3: Grand Composite Curve of HEN-1

In this diagram, there is a region above the pinch which is the LHS of the pinch

location and a region below the pinch which is the RHS of the pinch location. However, the

pinch location of HEN-1 grid diagram in Figure 4 is at the far end of the diagram and only

contains a region below the pinch. This indicates that the stream is not matched properly.

Moreover, the HEN-1 grid diagram shows no heat exchanger used across the pinch line,

indicating that the heat exchanger is placed properly.

Figure 4: Grid Diagram of HEN-1

HEN-2

Figure 5 shows the heat exchangers configuration showing all streams in HEN-2

network while Figure 6 displays the data extraction information for HEN-2.

Figure 5: PFD of HEN-2

Table 2: Problem Table of HEN-2

In Figure 6, there are excesses in both cold and hot utilities as the end curves show

varying enthalpy between hot and cold streams. This indicates that the utilities (energy

generated) are not utilised properly by the streams, a heat imbalance between the streams,

streams are not matched properly and process-to-process heat integration is inefficient.
 Figure 6: Composite curves of HEN-2

The GCC provides a graphical representation of the heat flow through the

process from hot utility to those parts of the process above the pinch point, and from the

process below the pinch point to the cold utility. In Figure 7, the pinch temperature is at

202C, indicating 0kW of enthalpy. In addition, the targeting report shows that the

minimum hot utility of 2817kW and minimum cold utility is -2817kW.

Figure 7: Grand Composite Curve of HEN-2

The grid diagram on Figure 8 shows a good representation of the pinch location,

where there is a region above (LHS) and below (RHS) the pinch line. When a cross pinch
analysis is applied, there are a total of 8 heat exchangers violating the pinch rule and

caused a pinch penalty of -2817.2kW heat energy not utilised.

Figure 8: Grid Diagram of HEN-2

HEN-3 (sims part)