heat integration chapter 9 s,s&l t&s section 3.5 terry ring university of utah
TRANSCRIPT
![Page 1: Heat Integration Chapter 9 S,S&L T&S Section 3.5 Terry Ring University of Utah](https://reader036.vdocuments.net/reader036/viewer/2022062322/56649cce5503460f94999fe0/html5/thumbnails/1.jpg)
Heat Integration
Chapter 9 S,S&L
T&S Section 3.5
Terry Ring
University of Utah
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Lost Work = Lost Money
• Transfer Heat from T1 to T2
• ΔT approach Temp. for Heat Exchanger• To= Temperature of Environment• Use 1st and 2nd laws of Thermodynamics
• LW=QToΔT/(T1T2)– ΔT=T1-T2
– To= Environment Temperature
• Q= UAΔTlm=UA (ΔT1-ΔT2)/ln(ΔT1/ΔT2)
T1
T2
Q
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Simple Heat Exchange Network (HEN)
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Costs
• Heat Exchanger Purchase Cost– CP=K(Area)0.6
• Annual Cost– CA=im[ΣCp,i+ ΣCP,A,j]+sFs+(cw)Fcw
• im=return on investment• Fs= Annual Flow of Steam,
– $5.5/ston to $12.1/ston = s
• Fcw=Annual Flow of Cold Water– $0.013/ston = cw
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Capital and Operating Cost Optimization
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Heat Integration
• Make list of HX• Instead of using utilities can you use
another stream to heat/cool any streams?• How much of this can you do without
causing operational problems?• Can you use air to cool?
– Air is a low cost coolant.
• Less utilities = smaller cost of operations
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2011
HPC REAC-2000
Q-2002
HPC VSSL-2000
2037
13
23
2024
XFS1
HPC SPLT-2001
30
2026
HPC PUMP-20002031
Q-2008
2012HPC RCYL-2001
2032
6
HPC MIX-2000
2009
3
1
2004
HPC XCHG-2002
HPC MIX-2001
2010
HPC CMPR-2000
2002Q-2001
7
2008HPC XCHG- 2000
HPC XCHG-2001
2038
2039
2040
2041
HPC XCHG-2003
2014
2025Q-2006
2050
2051
HPC XCHG-1008
HPC FAXR-2000
Q-2004
HPC FAXR-2002
Q-2005
HPC XCHG-2004
2042 2043
28
2052 2053HPC XCHG-2007
2048 2049
HPC FAXR-2001
HPC SPLT-2000
2016
2015
HPC MIX-2002
2018
2017
Q-2003HPC XCHG-2005
2044
2045
2019
HPC XCHG-20062020
2021
2046 2047 HPC VSSL-2001
HPC VSSL-2002
2022
HPC VSSL-2003
HPC XCHG-2009
Q-2007
2027
HPC RCYL-2002
2029
2101
HPC CMPR-2010
HPC MIX-20102102
HPC XCHG-2010
HPC XCHG-2011
2103
2104
2107
2108
HPC MIX-2011
2109 2110
HPC XCHG-2012
2114
2112
HPC VSSL-2010
HPC XCHG-2013
113
21052106
HPC SPLT-2010
HPC FAXR-2010
HPC FAXR-2011
HPC FAXR-2012
HPC MIX-2012
HPC VSSL-2011HPC VSSL-2012
HPC VSSL-2013
HPC XCHG-2016
2115
2116
2117
2118
2119
2120
2121
2122
21462147
2123
125
2124
2129
2128
2127
HPC RCYL-2012
HPC SPLT-2011
2130
2126
HPC PUMP-2010
2131
Q-21082137 HPC RCYL-2011
2132
2005
2111
HPC MIX-2003
HPC CMPR-2001
2033
2034
Q-2009
HPC XCHG-2014
HPC XCHG-2015
Q-2104
Q-2103
Q-2105
HPC XCHG-2017
2142 2143
144 145
2148 2149
2138 2139
2140
2141
Q-2101
HPC SPLT-2003
2135
2035
Q-2106
HPC XCHG-2018
2150 2151
Q-107
HPC XCHG-2019
2152 2153
Q-2102
HPC REAC-2010
HPC RCYL-2000
HPC RCYL-2010
2036
2136
XFS2
MIX-100
2
![Page 8: Heat Integration Chapter 9 S,S&L T&S Section 3.5 Terry Ring University of Utah](https://reader036.vdocuments.net/reader036/viewer/2022062322/56649cce5503460f94999fe0/html5/thumbnails/8.jpg)
2011
HPC REAC-2000
Q-2002
HPC VSSL-2000
2037
13
23
2024
XFS1
HPC SPLT-2001
30
2026
HPC PUMP-20002031
Q-2008
2012HPC RCYL-2001
2032
6
HPC MIX-2000
2009
3
1
2004
HPC XCHG-2002
HPC MIX-2001
2010
HPC CMPR-2000
2002Q-2001
7
2008HPC XCHG- 2000
HPC XCHG-2001
2038
2039
2040
2041
HPC XCHG-2003
2014
2025Q-2006
2050
2051
HPC XCHG-1008
HPC FAXR-2000
Q-2004
HPC FAXR-2002
Q-2005
HPC XCHG-2004
2042 2043
28
2052 2053HPC XCHG-2007
2048 2049
HPC FAXR-2001
HPC SPLT-2000
2016
2015
HPC MIX-2002
2018
2017
Q-2003HPC XCHG-2005
2044
2045
2019
HPC XCHG-20062020
2021
2046 2047 HPC VSSL-2001
HPC VSSL-2002
2022
HPC VSSL-2003
HPC XCHG-2009
Q-2007
2027
HPC RCYL-2002
2029
2101
HPC CMPR-2010
HPC MIX-20102102
HPC XCHG-2010
HPC XCHG-2011
2103
2104
2107
2108
HPC MIX-2011
2109 2110
HPC XCHG-2012
2114
2112
HPC VSSL-2010
HPC XCHG-2013
113
21052106
HPC SPLT-2010
HPC FAXR-2010
HPC FAXR-2011
HPC FAXR-2012
HPC MIX-2012
HPC VSSL-2011HPC VSSL-2012
HPC VSSL-2013
HPC XCHG-2016
2115
2116
2117
2118
2119
2120
2121
2122
21462147
2123
125
2124
2129
2128
2127
HPC RCYL-2012
HPC SPLT-2011
2130
2126
HPC PUMP-2010
2131
Q-21082137 HPC RCYL-2011
2132
2005
2111
HPC MIX-2003
HPC CMPR-2001
2033
2034
Q-2009
HPC XCHG-2014
HPC XCHG-2015
Q-2104
Q-2103
Q-2105
HPC XCHG-2017
2142 2143
144 145
2148 2149
2138 2139
2140
2141
Q-2101
HPC SPLT-2003
2135
2035
Q-2106
HPC XCHG-2018
2150 2151
Q-107
HPC XCHG-2019
2152 2153
Q-2102
HPC REAC-2010
HPC RCYL-2000
HPC RCYL-2010
2036
2136
XFS2
MIX-100
2
![Page 9: Heat Integration Chapter 9 S,S&L T&S Section 3.5 Terry Ring University of Utah](https://reader036.vdocuments.net/reader036/viewer/2022062322/56649cce5503460f94999fe0/html5/thumbnails/9.jpg)
Terms
• HEN=Heat Exchanger Network
• MER=Maximum Energy Recovery
• Minimum Number of Heat Exchangers
• Threshold Approach Temperature
• Optimum Approach Temperature
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Process
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Minimize UtilitiesFor 4 Streams
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Simple HEN
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Pinch Analysis1) Adjust Hot Stream Temperatures to Give ΔTmin
Order T’s, 250, 240, 235, 180, 150, 120
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Interval Heat Loads
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Enthalpy Differences for Temperature Intervals
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Pinch Analysis
Minimum Utilities
=ΔHi+50
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Pinch Analysis
ΔTapp
MER values
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Process
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How to combine hot with cold?
• Big Exhangers 1st
• 1st HX at Pinch (temp touching pinch)– Above Pinch Connect
• Cc≥Ch
– Below Pinch Connect• Ch≥Cc
• 2nd Hx or not touching Pinch temp.– No requirement for Cc or Ch
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4 Heat ExchangerHEN for Min. Utilities
Cc≥Ch Ch≥Cc
MER Values
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Pinch Analysis
Minimum Utilities
=ΔHi+50
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Minimum Utilities HEN
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Simple HEN
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Too Many Heat Exchangers
• Sometimes fewer Heat exchangers and increased utilities leads to a lower annual cost
• NHx,min= Ns + NU - NNW
– s=No. streams– U=No. discrete Utilities– NW=No. independent Networks (1 above the pinch, 1 below
the pinch)
• Solution to Too Many Heat Exchangers– Break Heat Exchanger Loops– Stream Splitting
• Attack small Heat Exchangers First
![Page 26: Heat Integration Chapter 9 S,S&L T&S Section 3.5 Terry Ring University of Utah](https://reader036.vdocuments.net/reader036/viewer/2022062322/56649cce5503460f94999fe0/html5/thumbnails/26.jpg)
Stream Splitting
• Two streams created from one
• one heat exchanger on each split of stream with couplings
1
1a
1b
1b
1a
1
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Break Heat Exchanger Loops
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Example
CP=K(Area)0.6
![Page 29: Heat Integration Chapter 9 S,S&L T&S Section 3.5 Terry Ring University of Utah](https://reader036.vdocuments.net/reader036/viewer/2022062322/56649cce5503460f94999fe0/html5/thumbnails/29.jpg)
Last Considerations
• How will HEN behave during startup?
• How will HEN behave during shutdown?
• Does HEN lead to unstable plant operation?
![Page 30: Heat Integration Chapter 9 S,S&L T&S Section 3.5 Terry Ring University of Utah](https://reader036.vdocuments.net/reader036/viewer/2022062322/56649cce5503460f94999fe0/html5/thumbnails/30.jpg)
2011
HPC REAC-2000
Q-2002
HPC VSSL-2000
2037
13
23
2024
XFS1
HPC SPLT-2001
30
2026
HPC PUMP-20002031
Q-2008
2012HPC RCYL-2001
2032
6
HPC MIX-2000
2009
3
1
2004
HPC XCHG-2002
HPC MIX-2001
2010
HPC CMPR-2000
2002Q-2001
7
2008HPC XCHG- 2000
HPC XCHG-2001
2038
2039
2040
2041
HPC XCHG-2003
2014
2025Q-2006
2050
2051
HPC XCHG-1008
HPC FAXR-2000
Q-2004
HPC FAXR-2002
Q-2005
HPC XCHG-2004
2042 2043
28
2052 2053HPC XCHG-2007
2048 2049
HPC FAXR-2001
HPC SPLT-2000
2016
2015
HPC MIX-2002
2018
2017
Q-2003HPC XCHG-2005
2044
2045
2019
HPC XCHG-20062020
2021
2046 2047 HPC VSSL-2001
HPC VSSL-2002
2022
HPC VSSL-2003
HPC XCHG-2009
Q-2007
2027
HPC RCYL-2002
2029
2101
HPC CMPR-2010
HPC MIX-20102102
HPC XCHG-2010
HPC XCHG-2011
2103
2104
2107
2108
HPC MIX-2011
2109 2110
HPC XCHG-2012
2114
2112
HPC VSSL-2010
HPC XCHG-2013
113
21052106
HPC SPLT-2010
HPC FAXR-2010
HPC FAXR-2011
HPC FAXR-2012
HPC MIX-2012
HPC VSSL-2011HPC VSSL-2012
HPC VSSL-2013
HPC XCHG-2016
2115
2116
2117
2118
2119
2120
2121
2122
21462147
2123
125
2124
2129
2128
2127
HPC RCYL-2012
HPC SPLT-2011
2130
2126
HPC PUMP-2010
2131
Q-21082137 HPC RCYL-2011
2132
2005
2111
HPC MIX-2003
HPC CMPR-2001
2033
2034
Q-2009
HPC XCHG-2014
HPC XCHG-2015
Q-2104
Q-2103
Q-2105
HPC XCHG-2017
2142 2143
144 145
2148 2149
2138 2139
2140
2141
Q-2101
HPC SPLT-2003
2135
2035
Q-2106
HPC XCHG-2018
2150 2151
Q-107
HPC XCHG-2019
2152 2153
Q-2102
HPC REAC-2010
HPC RCYL-2000
HPC RCYL-2010
2036
2136
XFS2
MIX-100
2
![Page 31: Heat Integration Chapter 9 S,S&L T&S Section 3.5 Terry Ring University of Utah](https://reader036.vdocuments.net/reader036/viewer/2022062322/56649cce5503460f94999fe0/html5/thumbnails/31.jpg)
Optimization of HEN
• How does approach ΔT (ΔTmin) effect the total cost of HEN?
• Q= UA ΔT
• LW=QToΔT/(T1T2)
– More Utility cost
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ΔTmin
• S T(C) T(C) CQ(kW)
• H1 300 200 1.5 150
• H2 300 250 2 100
• C1 30 200 1.2 204
LW=QToΔT/(T1T2)
ΔTapp=10C ΔTapp=105C
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Costs
• Heat Exchanger Purchase Cost– CP=K(Area)0.6
• Annual Cost– CA=im[ΣCp,i+ ΣCP,A,j]+sFs+(cw)Fcw
• im=return on investment• Fs= Annual Flow of Steam,
– $5.5/ston to $12.1/ston
• Fcw=Annual Flow of Cold Water– $0.013/ston
![Page 34: Heat Integration Chapter 9 S,S&L T&S Section 3.5 Terry Ring University of Utah](https://reader036.vdocuments.net/reader036/viewer/2022062322/56649cce5503460f94999fe0/html5/thumbnails/34.jpg)
Change ΔTmin
CP=K(Area)0.6
Area=Q/(UF ΔTmin)
More Lost Work
LW=QToΔT/(T1T2)
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Capital and Operating Cost Optimization
ΔTthres
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Distillation Columns
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Heuristic “Position a Distillation Column Between Composite Heating and Cooling Curves”
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Heat Integration for Indirect Distillation Sequence
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Multi-effect DistillationAdjust Pressure in C2 for ΔTmin
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• Heat Pumps in Distillation
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Heat PumpsHow do they work?
Convert low temperature heat to high temperature heat.Must add work as heat can not go up hill.
Same as Air Conditioner
Carnot Efficiencyηmax= 1-Tc/Th
Endoreversibleη =1-√(Tc/Th)
![Page 42: Heat Integration Chapter 9 S,S&L T&S Section 3.5 Terry Ring University of Utah](https://reader036.vdocuments.net/reader036/viewer/2022062322/56649cce5503460f94999fe0/html5/thumbnails/42.jpg)
Heat Pumps/Heat Engines Heurisitcs
• When positioning heat engines, to reduce the cold utilities, place them entirely above or below the pinch
• When positioning heat pumps, to reduce the total utilities, place them across the pinch.
![Page 43: Heat Integration Chapter 9 S,S&L T&S Section 3.5 Terry Ring University of Utah](https://reader036.vdocuments.net/reader036/viewer/2022062322/56649cce5503460f94999fe0/html5/thumbnails/43.jpg)
Heat PumpsWhere can they be used?
•Heuristic
•When positioning heat pumps, to reduce the total utilities, place them across the pinch.
![Page 44: Heat Integration Chapter 9 S,S&L T&S Section 3.5 Terry Ring University of Utah](https://reader036.vdocuments.net/reader036/viewer/2022062322/56649cce5503460f94999fe0/html5/thumbnails/44.jpg)
Heat EnginesWhere can they be used?
•Heuristic
•When positioning heat engines, to reduce the cold utilities, place them entirely above or below the pinch
Tp