Lecture 09+

LECTURE NINE
054402 Design and Analysis
LECTURE 9: HEAT & POWER INTEGRATION

Daniel R. Lewin Department of Chemical Engineering Technion, Haifa, Israel
DESIGN AND ANALYSIS - (c) Daniel R. Lewin
9 - Heat & Power Integration
Schedule Heat and Power Integration Unit 6. Data Extraction

Class Exercise 8
Unit 7. Heat Integration in Design

Grand Composite Curves (GCCs) Heat-integrated Distillation Heat Engines Heat Pumps
Daniel R. Lewin, Technion
LECTURE NINE
Instructional Objectives This Unit on HEN synthesis serves to expand on what was covered in the last two weeks to more advanced topics. Instructional Objectives - You should be able to: Extract process data (from a flowsheet simulator) for HEN synthesis Understand how to use the GCC for the optimal selection of utilities Have an appreciation for how HEN impacts on design
UNIT 6: Data Extraction

Process analysis begins with the extraction of hot and cold streams from a process flowsheet Required: The definition of the hot and cold streams and their corresponding TS and TT CP for each stream is either approximately constant or H=f(T).
4 DESIGN AND ANALYSIS - (c) Daniel R. Lewin 9 - Heat & Power Integration
LECTURE NINE
What is considered to be a stream ?

In general: Ignore existing heat exchangers
Mixing: Consider as two separate streams through to target temperature.
Splitting: Assume a split point wherever convenient.
Example Dealing with Real Systems
o Toluene is manufactured by dehydrogenating n-heptane. o Furnace E-100 heats S1 to S2, from 65 oF to 800 oF. o Reactor effluent, S3, is cooled from 800 oF to 65 oF. o Install a heat exchanger to heat S1 using S3, and thus reduce the required duty of E-100. a) Generate stream data using piece-wise linear approximations for the heating and cooling curves for the reactor feed and effluent streams. b) Using the stream data, compute the MER targets for Tmin = 10 oF.
LECTURE NINE

Equivalent, piece-wise flowing heat capacity:
C =
k
Heating of liquid
h h T T
k +1 k k +1
Heating of vapor Evaporation of n-heptane

Equivalent, piece-wise flowing heat capacity:
C =
k
h h T T
k +1 k k +1
Cooling of vapor
Condensation
LECTURE NINE

Equivalent, piece-wise flowing heat capacity: C =
k
h h T T
k +1 k k +1

(b) MER Targeting:
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LECTURE NINE
Class Exercise 8
a) Extract data for hot and cold streams from the flowsheet below. b) Assuming Tmin = 10o, compute the pinch temperatures,
QHmin and QCmin. c) Retrofit the existing
50o
W
network to meet MER.
CP = 0.4 40o
C
130o CP = 1.0
100o 125o
H
H = 100 H = 100
H
150o
30o
140o
11 DESIGN AND ANALYSIS - (c) Daniel R. Lewin
CP = 0.6
Class Exercise 8 - Solution

50o
W
CP = 0.4 40
o
130o CP = 1.0
100o 125o
H
H = 100 H = 100
H
150
30o
140
CP = 0.6
Tmin = 10 oC
S TS ( C)
o o
Stream
Feed Bottoms Cond Recyc Reb
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TT TT o ( oC) ( C) 100 30 40 140 150
H H (kW) (kW) 30 72 100 36 100
CP (kW/oC) 1.0 0.6 0.4
130 150 40 50 150
LECTURE NINE
Class Exercise 8 - Solution (Contd)

Stream
Feed Bottoms Cond Recyc Reb
T (oC) 130 150 40 50 150
Tmin = 10 oC
T (oC) 100 30 40 140 150
T
H (kW) 30 72 100 36 100
CP (kW/oC) 1.0 0.6 0.4
T1 = 150oC
QH
Assume QH = 0
H = -100
Eliminate infeasible (negative) heat transfer QH = 100
H = 0 T2 = 140oC Q1 -100 0
H = 4 Q2 T3 = 120oC H = 36 Q3 T4 = 90oC H = 8 -60 40 -96 4
This defines: Cold pinch temperature = 140oC QHmin = 100 kW QCmin = 166 kW
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T5 = 50oC
Q4
-52
48
H = 12 Q5 T6 = 30 C
o
60
160
H = +100
H = 6 T7 = 20 C
o
QC
66
166

HEN Representation of existing flowsheet
CP Feed Botts Cond 130
o
100o 1.0 30
o
150o 40o 140o
0.6 0.4
40o
Recy
150o
150o
Reb
QHmin = 100
QCmin = 166
LECTURE NINE

HEN Representation of existing flowsheet
CP Feed Botts Cond 130o 150o 40o 140o 150
o
100o 1.0 30
o
0.6 0.4
40o
Recy
150o
Reb
QHmin = 100
QCmin = 166
UNIT 7: Heat Integration in Design The Grand Composite Curve

An enthalpy cascade for a process is shown on the right. Note that QHmin = QCmin = 1,000 kW Also, TC,pinch = 190 oC
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LECTURE NINE
The Grand Composite Curve (Contd)

The Grand Composite Curve presents the same enthalpy residuals, as follows: Minimum external heating, at 310 oC Internal heat exchange TC,pinch Internal heat exchange
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Alternative heating and cooling utilities can be used, to reduce operating costs:
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LECTURE NINE

Example:
GCC:
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GCC Example (Contd)

Possible designs using CW and HPS: Umin = 4 + 2 1 = 5 How many loops?
Does this design meet Umin ? If not, what is the simplest change you can make to fix it?
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LECTURE NINE
GCC Example (Contd)

Returning to the GCC:
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GCC Example (Contd)

Possible designs using CW, BFW, LPS and HPS:
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LECTURE NINE
UNIT 7: Heat Integration in Design Heat-integrated Distillation

Distillation is highly energy intensive, having a low thermodynamic efficiency (as little as 10% for a difficult separation), but is widely used for the separation of organic chemicals in large-scale processes. Thermal integration of columns can be done by manipulation of operating pressure. Note: Qreb Qcond for columns with saturated liquid products.
Need to position column carefully on composite curve
Heat-integrated Distillation (Contd)

Option A: Position distillation column between hot and cold composite curves:
(a) Exchange between hot and cold streams

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(b) Exchange with cold streams
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LECTURE NINE

Option B: 2-effect distillation: (a) Tower and heat exchanger configuration; (b) T-Q diagram.
25

Option C: Distillation configurations involving compression: (a) heat pumping (a) heat pumping (b) vapor recompression (b) vapor recompression (c) reboiler flashing (c) reboiler flashing
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LECTURE NINE

Option C: Distillation configurations involving compression:
(a) heat pumping
(b) vapor recompression
(c) reboiler flashing
All 3 configurations involve the expensive compression of a vapor stream. May not be cost-effective except where pressure changes required are small. Example: separation of closeboiling mixtures
UNIT 7: Heat Integration in Design Heat Engines and Heat Pumps

When processes have significant power demands, normally sound practice to operate at or near minimum utilities. Let us consider alternative placement of heat engines and heat pumps.
Heat Engine
Heat Pump
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LECTURE NINE
Heat Engines and Heat Pumps (Contd)
Alternatives for the placement of heat engines: (a) Above Tpinch; (b) Across Tpinch; (c) Below Tpinch
Alternatives for the placement of heat pumps: (a) Above Tpinch; (b) Below Tpinch ;(c) Across Tpinch
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LECTURE NINE

These results lead to the following general recommendations for the placement of heat engines and heat pumps relatively to the pinch: Townsend and Linnhoff heuristics: To reduce the total utilities, place heat engines entirely above or below the pinch To reduce the total utilities, place heat pumps across the pinch
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Heat and Power Integration - Summary Unit 6. Data Extraction Getting data for HEN synthesis from material and energy balances (i.e., from simulator) Unit 7. Heat Integration in Design Use of Grand Composite Curves for selection of utilities Options for heat-integrated distillation Optimal positioning of heat engines and heat pumps
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LECTURE NINE

054402 Design and Analysis

054402 Design and Analysis

LECTURE 9: HEAT & POWER INTEGRATION

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

9 - Heat & Power Integration

Schedule Heat and Power Integration Unit 6. Data Extraction

Unit 7. Heat Integration in Design

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

9 - Heat & Power Integration

Daniel R. Lewin, Technion

054402 Design and Analysis

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

9 - Heat & Power Integration

UNIT 6: Data Extraction

Daniel R. Lewin, Technion

054402 Design and Analysis

What is considered to be a stream ?

Mixing: Consider as two separate streams through to target temperature.

Splitting: Assume a split point wherever convenient.

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

9 - Heat & Power Integration

Example Dealing with Real Systems

Daniel R. Lewin, Technion

054402 Design and Analysis

Example Dealing with Real Systems

Heating of vapor Evaporation of n-heptane

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

9 - Heat & Power Integration

Example Dealing with Real Systems

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

9 - Heat & Power Integration

Daniel R. Lewin, Technion

054402 Design and Analysis

Example Dealing with Real Systems

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

9 - Heat & Power Integration

Example Dealing with Real Systems

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

9 - Heat & Power Integration

Daniel R. Lewin, Technion

054402 Design and Analysis

network to meet MER.

Class Exercise 8 - Solution

TT TT o ( oC) ( C) 100 30 40 140 150

H H (kW) (kW) 30 72 100 36 100

CP (kW/oC) 1.0 0.6 0.4

130 150 40 50 150

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

9 - Heat & Power Integration

Daniel R. Lewin, Technion

054402 Design and Analysis

Class Exercise 8 - Solution (Contd)

T (oC) 130 150 40 50 150

H (kW) 30 72 100 36 100

CP (kW/oC) 1.0 0.6 0.4

Eliminate infeasible (negative) heat transfer QH = 100

H = 4 Q2 T3 = 120oC H = 36 Q3 T4 = 90oC H = 8 -60 40 -96 4

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

9 - Heat & Power Integration

Class Exercise 8 - Solution (Contd)

150o 40o 140o

Daniel R. Lewin, Technion