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I General Introduction
II Optimization prior-Design:
Extended Models
I General Introduction
Actual=XP + Target
GRAND COMPOSITE
BALANCED COMPOSITES
RECONCILE/BALANCED GRID
Design
I General Introduction
1.1 Pinch Technology UNIVERSIDAD
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Interval I 2
A B C D E F
Enthaphy
Ai = Hi/(U.TLM.i)
The global minimum network area is given by:
Atot=(1/U)intervalsi (H.i/.TLM.i)
If the heat transfer coefficients differ, then for a match between
stream i and stream j the global heat transfer coefficient (Uij ) is:
Area
z
Crossing Pinch:
You have used cold water to
P Q decrease the temperature of a hot
stream from above the pinch region.
R
Energy
Energy Cost
The resulting cost profile displays Network
a minimum at some value of Tmin Capital Cost (V. M.)
approach to the
Targets during the minimum overall area
now = am + Ar,m
II Optimization prior-Design:
Extended Models
Tjhj=, j=1,,Si 4
and 5
6
Sij=1CPj(Tj-Tk)=0,
Tj*=T4 + T4 +( - ) Tj
where
S I = number of streams at enthalpy
interval edge i, The temperature at T*j at which
stream j now crosses the interval
Cpj = heat capacity flow rate of stream j, edge i is then given as follos:
k = stream which causes the enthalpy
interval i.
Tj*=Tk -Tk+Tj
The Area Target is again predicted with equation:
Atot.min=intervalsi (1/TLM.i) jstreams(qj/hj)i
II Extended Models
2.1 Non Vertical Heat Transfer UNIVERSIDAD
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Annual Cost
Capital cost
LP model
The area target is usually less than the area observed in design.
The cost of the special heat exchanger can be determined from the
reference cost law using a modified area:
A* = [(b2/b1)1/c1 A(c2/c1) 1]A
II Extended Models
2.4 Stream specific cost-weighting factors. UNIVERSIDAD
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Where
hot = cold The result is as accurate
as the cost laws
Simplifying to:
Cost laws can often be adjusted
j = (b1/b2)1/c such that c is constant
Design or Re-
Re-design (apply
Pinch principles) the network
Yes!
Calculate the target capital cost for mixed Calculate -factors for
those streams with different
specification heat exchanger network
specifications
Expensed
Engineering
Trash
Capitalized
Engineering
Research
Market Analysis
Computer Simulation
Software Programming
Equipment Design
Cost Estimation
Profitability Analysis
Technical Communications
III Design and Economics
3.1 Process Economics: Introduction UNIVERSIDAD
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Essential variables:
No design should
Raw materials
proceed beyond the
Waste products preliminary stage
By products without a consideration
Societal Need
Equipment of costs!!
Plant location
Costs
Time factors
Process considerations
III Design and Economics
3.1 Process Economics: Introduction UNIVERSIDAD
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www.usfca.edu/usf/library/research/econstats.html
III Design and Economics
3.2 Analysis of cost estimation UNIVERSIDAD
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The engineer
must recommend
the production
rate and
operating
schedules that
will give optimal
economic results
The point where the total product cost equals the total
income is designated as the breakeven point
III Design and Economics
3.2 Analysis of cost estimation UNIVERSIDAD
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A cost index is an index value for a given time showing the cost at
that time relative to a certain base time:
Present cost = original cost ( index value at present / index value at original time)
www.che.com
III Design and Economics
3.2 Analysis of cost estimation UNIVERSIDAD
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Cn=(E+f1E+f2E+f3E+ + fnE)
The percentage of
delivered equipment cost methods
depend on the cost for the major
equipment items provided by the
user (the Lang Factor is included
in this methods), as determined
from the material and energy
balances and equipment operating
characteristics.
III Design and Economics
3.2 Analysis of cost estimation UNIVERSIDAD
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1. Manufacturing cost
2. General expenses
III Design and Economics
3.2 Analysis of cost estimation UNIVERSIDAD
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I = PiN
F = ( 1+ r/m )m
F = (1 + ieff )n
III Design and Economics
3.3 Time value of money, taxes, and fixed charges. UNIVERSIDAD
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F = Pe rN = P(1 + ieff ) N
III Design and Economics
3.3 Time value of money, taxes, and fixed charges. UNIVERSIDAD
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Discrete compounding P = F (1 + i ) N
Continuous compounding rN
P = Fe
III Design and Economics
3.3 Time value of money, taxes, and fixed charges. UNIVERSIDAD
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[per year]
III Design and Economics
3.3 Time value of money, taxes, and fixed charges. UNIVERSIDAD
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A j = ( s j c0 j )(1 ) + d j
j indicates an annual value in year j, A is the annual cash
flow, s the annual sales revenue, c0 the operating cost
(except depreciation)
III Design and Economics
3.3 Time value of money, taxes, and fixed charges. UNIVERSIDAD
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Calculating depreciation
d = V/n
V -the original investment in the property
d -the annual depreciation in dollars per day
III Design and Economics
3.3 Time value of money, taxes, and fixed charges. UNIVERSIDAD
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The payback period is the length of time necessary for the total return to
equal the capital investment. Cash flow changes from year to year, the
PBP is obtained with the average cash flow -(Aj)ave being V + Ax the fixed
capital investment.
V + A
PBP = x
( A j ) ave
Net present worth is the total of the present worth of all cash flows
minus the present worth of all capital investments:
N N
NPW = PWFcf , j [( s j coj d j )(1 ) + rec j + d j ] PWFv , j F j
j =1 j = 1
Ahmad S. Heat exchanger networks: cost tradeoffs in energy and capital. Ph.D. Thesis, University of
Manchester Institute of Science and Technology, U.K. (1985).
Ahmad S.,Linnhoff B., and Smith R. Design of multipass heat exchangers: an alternative approach. J. Heat
Transfer (ASME) 110, 304-309 (1988).
Linhoff B., and Ahmad S. Cost optimum heat exchanger networks 1. Minimum energy and capital using
simple models for capital cost. Computers Chem. Engng. Vol. 14, No. 7, pp 729-750 (1990).
Linhoff B., and Ahmad S. Cost optimum heat exchanger networks-2. Target and design for detailed capital
cost models. Computers Chem. Engng.Vol. 14, No. 7, pp 751-767 (1990).
Linhoff B. Pinch technology has come of age. Chemical Engineering Progress, pp 33-40, July 1984.
Linhoff B. User guide on process integration for the efficient use of energy. Institution of Chemical
Engineers. UK (1994).
Morgan S. Use process integration to improve process design and the design process. Chemical
Engineering Progress, pp 62-68, sep. (1992).
Peters M., Timmerhaus K. West R. Plant Design and Economics for Chemical Engineers. Mc Graw Hill, Fifth
ed., USA (2003).
UNIVERSIDAD
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I. Problem Introduction
III. Conclusions
I Problem Introduction
UNIVERSIDAD
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Develop a table with all of the hot streams broken down into
temperature intervals.
Sum all of the CP values for each of the temperature intervals and
calculate Q
Sum each of the successive Q values to find total Q for the 5 hot
streams
Table 3. Hot Composite Curve Data
250
200
Temp ( oC)
150
100
50
0
0 5000 10000 15000 20000 25000 30000
Q (kW)
i oC 6 7 8 9 CP Qi Q
0 30 - - - - 0 0 0
250
200
Temp ( oC)
150
100
50
0
0 10000 20000 30000 40000
Q (kW)
250
200
Temp ( C)
150
o
CCC
HCC
100
50
0
0 10000 20000 30000 40000
Q (kW)
Figure 3. Balanced Composite Graph
II Solution Technique
2.2 Pinch Point Analysis UNIVERSIDAD
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Industry Tmin
We will use
Oil Refining 30-40oC
Tmin=20oC for the
initial value.
Petrochemical 10-20oC
Chemical 10-20oC
Low-temp 3-5oC
II Solution Technique
2.2 Pinch Point Analysis UNIVERSIDAD
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This initial table takes the shifted temperature values and combines them
with all of the streams, hot and cold. For each stream CP values are put
within the streams temperature range with negative CP values used for
the hot streams and positive CP values used for cold streams. A total CP
value is then calculated for each interval.
Table 7. Pinch Point Table
CP 50 300 290 20 260 150 140 100 50
interval temp 1 2 3 4 5 6 7 8 9 CP
1 220 - - - - - - - 100 - 100
2 210 - - - -20 - - 140 100 - 220
12 40 - - - - - - - - - 0
II Solution Technique
2.2 Pinch Point Analysis UNIVERSIDAD
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It is then required to calculate the Q for each interval using the CP and
the temperatures bounding the interval. A hot utility value of zero is first
placed in the column below Q then each successive Q value is subtracted
from the previous Q value. This is continued to the last interval where the
Q value represents the cold utility.
Table 8. Pinch Point Table cont.
Q
interval temp CP Qi 0
12 40 0 0 -13950
II Solution Technique
2.2 Pinch Point Analysis UNIVERSIDAD
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From the previous table the most negative Q value is turned positive and
is used as the hot utility. The same calculations are made where each
successive Q value is subtracted from the previous Q value. The zero Q
value represents the pinch point. The utility values calculated will be used
in the next part of the solution.
Table 9. Pinch Point Table Cont.
Q
50 - - - - - - 0 0 0
65 - - 300 - - - 300 4500 4500
80 - 50 300 - - - 350 5250 9750
95 - 50 - - - - 50 750 10500
105 - 50 - - 20 - 70 700 11200
110 - 50 - - 20 260 330 1650 12850
120 - 50 - 290 20 260 620 6200 19050
135 - - - 290 20 260 570 8550 27600
220 - - - - 20 - 20 1700 29300
249 - - - - - - 0 0 29300
90 150 140 100 50 - 440 6600 20350 11200 66.5 105.0 38.5
140 - 140 100 50 - 290 14500 34850 12850 72.0 110.0 38.0
200 - 140 100 - - 240 14400 49250 13750 75.0 111.5 36.5
210 - - 100 - - 100 1000 50250 19050 87.0 120.0 33.0
20350 90.0 122.3 32.3
300.0
250.0
200.0
Temp ( C)
o
BCCC
150.0
BHCC
100.0
50.0
0.0
0 10000 20000 30000 40000 50000
Q (kW)
Amin = 9523.77
II Solution Technique
2.5 Nunits Calculation UNIVERSIDAD
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80o 50o
135o 110o
220o 95o
135o 105o
90o 65o
200o 75o
210o 30o
140o 60o
Pinch
Figure 6. System Temp. Flow Diagram 135o
Nunits= (4 + 1 - 1) + (9 + 1 - 1) = 13
II Solution Technique
2.6 Capital Cost Calculations UNIVERSIDAD
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cost of a system a b c
operating at Tmin
Carbon-steel 30800 750 0.81
Stainless-steel 30800 1644 0.81
consists of using the CS/SS or SS/CS 30800 1339 0.81
following equation and Titanium 30800 4407 0.81
For CS construction:
Cost ($)=13 (30800 + 750*(9523.77/13)0.81
Cost ($)=2440003
II Solution Technique
2.6 Capital Cost Calculations UNIVERSIDAD
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TI = (bCS/bTI) (1/cTI)
(S.G. Hall, S. Ahmad and R. Smith, 1989)
TI = (750/4407) (1/0.81)
TI = 0.1123
II Solution Technique
2.7 Multiple Materials Construction UNIVERSIDAD
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streams CPj T
1
Temperature Interval Area=
TLM j j hj
(S.G. Hall, S. Ahmad and R. Smith, 1989)
II Solution Technique
2.7 Multiple Materials Construction UNIVERSIDAD
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CS 9523.768 2440003
The table below shows the data translated into cost figures using methods
previously discussed. The minimum Total Cost corresponds to the optimal Tmin.
Table 21 Tmin Optimization Cost Analysis
Qc Qh Utility Sum CC ACC Total Cost
Tmin ($/yr) ($/yr) ($/yr) ($/6yr) ($/yr) ($/yr)
28 93200 2792400 2885600 4067489 1200968 4086568
26 87400 2722800 2810200 4185583 1235836 4046036
24 81600 2653200 2734800 4319463 1275366 4010166
22 75800 2583600 2659400 4473447 1320831 3980231
20 70000 2514000 2584000 4655655 1374629 3958629
18 64500 2448000 2512500 4869284 1437706 3950206
16 61500 2412000 2473500 5008682 1478864 3952364
14 57000 2358000 2415000 5257518 1552336 3967336
12 51000 2286000 2337000 5658733 1670799 4007799
10 45000 2214000 2259000 6180645 1824898 4083898
9 42000 2178000 2220000 6492346 1916931 4136931
8 39000 2142000 2181000 6865036 2026972 4207972
6 33000 2070000 2103000 7888767 2329239 4432239
4 26500 1992000 2018500 9531058 2814142 4832642
2 19500 1908000 1927500 13161489 3886064 5813564
0 12500 1824000 1836500 53263934 15726718 17563218
II Solution Technique
2.9 Tmin Optimization UNIVERSIDAD
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8
7
6
Cost (*106 $/year)
5 OC
4 CC
3 TC
2
1
0
0 5 10 15 18 20 25 30
Tmin (oC)
135o 105o
90o 65o
62o
TC = 845489 + 4791104
TC = 5636593
II Solution Technique
2.11 Profitability Analysis UNIVERSIDAD
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ATPC = 3012500
II Solution Technique
2.11 Profitability Analysis UNIVERSIDAD
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NPAT
Table 32. %ROR
DF = (1 + i )
j
(Peters, Timmerhaus and West, 2003)
NPW = $5069829
II Solution Technique
2.11 Profitability Analysis UNIVERSIDAD
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The calculations for the DCFR are made easier by using the
Solver add-in in Microsoft Excel. The table below shows the
setup with the previous data and the interest of 10%.
Using solver, target the value of Net Present Worth to zero
by changing the value of Mar.
This is possible since all of the Discounting Factors are
calculated by using the Mar as the interest value.
Table 35. DCFR Calculations
Year 1 2 3 4 5 6 7
Net Cash Flow ($) 2221356 2407677 2252410 2148898 2107493 2107493 2024684
Discounting Factor ($) (1-Mar)1 0.8264 0.7513 0.6830 0.6209 0.5645 0.5132
Discounted Cash Flow
($) 2019415 1989816 1692269 1467726 1308588 1189625 1038983
S. G. Hall, S. Ahmad and R. Smith. Capital Cost Targets For Heat Exchanger Networks Comprising Mixed
Materials of Construction, Pressure Ratings, and Exchanger Types. Computers Chemical
Engineering. Vol. 14, No. 3, pp. 319-335, Great Britain, 1990.
Peters, Timmerhaus, West. Plant Design and Economics for Chemical Engineers, pp. 226-335. New York
2003.
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I. Problem Introduction
The data below contains the stream data for the open-ended
problem. It must also be noted that 1,5, and 6 require carbon
steel plate and frame exchangers while the rest are sufficient
with carbon steel shell and tube exchangers.
Topt
%ROR
NPW
DCFR
II Desired Results
UNIVERSIDAD
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Haslego, C. Polley, G. T. Compact Heat Exchangers, Part 2: Using Plate Exchangers in Heat Recovery
Networks. CEP Magazine. Vol. 98, pp. 48-51, October 2002.
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The End
EL FINAL
Le Fin