CDB 3044 : PROCESS PLANT DESIGN

Heat Integration (II)

1
 Learning Outcomes
At the end of this lecture, student should be able to

 Perform heat integration calculation to determine the minimum utility

requirements and maximum heat recovery for the process.

 Design Heat Exchanger Network for Maximum Energy Recovery.

2
HEAT INTEGRATION ENERGY TARGETS – Multiple Utilities

Different processes normally use multiple levels of utilities.

Fuel & Air

HP Steam
STEAM TURBINE
GAS TURBINE W MP Steam
W
LP Steam

Q+W
HEAT PUMP

FURNACE W
PROCESS

Air Preheat

Refrigeration

Fuel W

Q+W
COOLING TOWER
3
HEAT INTEGRATION ENERGY TARGETS – Composite Curve

Composite curve method only tells us the amount of utility required to satisfy the process requirement. But it does not tell us
the mix utilities that can be used.
T

1600 3000 1000

180

960 (Hot Utility)

130
120

100

80
Minimum temperature difference = 10 oC
60

40
30

120 (Cold Utility)

1080 4640 720 H

4
HEAT INTEGRATION ENERGY TARGETS – Problem Table Algorithm

And so does the problem table algorithm.

960 QH
Stream Population ΔTint Σ CpC - Σ CpH ΔHint Surplus/Deficit
175 o C
175 o C

50 -20 -1000 Surplus

ΔH = - 1000

125 o C 125 o C 1960

20 -24 -480 Surplus ΔH = - 480

105 o C 2440
105 o C
30 56 1680 Deficit
ΔH = 1680
75 oC
20
75 o C 760
10 76 760 Deficit

65 o C ΔH = 760
80
30 -4 -120 Surplus 65 o C 0
35 o C
40 36 ΔH = -120
35 o C 120

120 QC
5
HEAT INTEGRATION ENERGY TARGETS – Grand Composite Curve

To enable designer to determine the various utilities mix that can be used, Grand Composite Curve
is useful.

Consider again the problem below.

Cp Q
180 o C 80 o C
HOT 1 20 2000

130 o C 40 o C
HOT 2 40 3600

120 o C 30 o C 36 3240
COLD 1

100 o C 60 o C
COLD 2 80 3200

From the problem table algorithm, the heat cascade was derived.

6
 HEAT INTEGRATION ENERGY TARGETS – Grand Composite Curve

0 960 QH

175 o C 175 o C

ΔH = - 1000 ΔH = - 1000
Adjust the heat cascade
125 o C 1000 125 o C 1960

ΔH = - 480 ΔH = - 480

105 o C 1480 105 o C 2440

ΔH = 1680 ΔH = 1680

75 o C -200 75 o C 760

ΔH = 760 Highest –ve value for heat accumulated ΔH = 760

65 o C -960 65 o C 0

ΔH = -120 ΔH = -120
35 o C -840 35 o C 120

120 QC
The adjusted heat cascade is used to develop the Grand Composite Curve.
7
 HEAT INTEGRATION ENERGY TARGETS – Grand Composite Curve

T Grand Composite Curve

960 QH
960
175 o C 175 o C

ΔH = - 1000
1960
125 oC 1960 125 oC

Δ H = - 480
2440
105 o C 2440 105 o C

Δ H = 1680
760
oC oC
75 760 75

Δ H = 760
65 o C 0 65 o C

Δ H = -120
35 o C 120 35 o C
120
120 QC H

8
 HEAT INTEGRATION ENERGY TARGETS – Grand Composite Curve

How do we use them ?

960 We don’t necessarily have to supply the heating

175 o C utility at this temperature

Lowest temperature where 1960

hot utility could be 125 o C Heat Recovery/
supplied and still satisfy QH = 960
Process to Process Heat
the heating requirement. Transfer 2440
105 o C

75 o C
760
65 o C

35 o C
120
H
9
HEAT INTEGRATION ENERGY TARGETS – Utility Selection and Targeting
If we decide to use hot flue gas either from furnace or gas turbine exhaust,

TTFT or TGT
T
Flue gas source temperature i.e. Furnace flame temp.
(TFT) or Gas Turbine exhaust temp (TGT).

Slope = 1/mCp of flue gas

175 o C 960

1960
125 o C
QH = 960 Heat Recovery/
Process to Process Heat 2440
105 o C
Transfer

75 o C

760
65 oC

35 o C
QC = 120
H
10
HEAT INTEGRATION ENERGY TARGETS – Utility Selection and Targeting

Example:

Cp Q
250 o C 40 o C
HOT 1 15 3150

200 o C 80 o C
HOT 2 25 3000

180 o C 20 o C 20 3200
COLD 1

230 o C 60 o C
COLD 2 30 2700

11
HEAT INTEGRATION ENERGY TARGETS – Utility Selection and Targeting

Solution:
0 750

245 o C 245 o C
ΔH = - 150 ΔH = - 150

235 o C 150 235 o C 900

ΔH = 600 ΔH = 600
195 o C -450 195 o C 300
ΔH = - 100 ΔH = - 100
Adjust the heat cascade
185 o C -350 185 o C 400
ΔH = 400 ΔH = 400
Highest –ve value for
145 o C -750 145 o C -0
heat accumulated
ΔH = -1400 ΔH = -1400

75 o C 650 75 o C 1400
ΔH = 200 ΔH = 200

35 o C 450 35 o C 1200

ΔH = 200 ΔH = 200
25 oC
25 oC
250 1000

250 1000

12
 HEAT INTEGRATION ENERGY TARGETS – Utility Selection and Targeting
Solution:
The Grand Composite Curve
750 QH
T
750
245 oC 245 o C
900 ΔH = - 150
235 o C
235 o C 900
300 ΔH = 600
195 o C
400 195 o C 300
185 o C Δ H = - 100
Process to Process 185 o C 400
Heat Transfer
Δ H = 400
145 o C
145 o C -0
Δ H = -1400

75 o C 1400
1400 Δ H = 200
75 o C
35 o C 1200

Δ H = 200
35 o C 1200 25 oC
1000

25 o C 1000 ΔH
1000 QC
13
HEAT INTEGRATION ENERGY TARGETS – Utility Selection and Targeting

Solution: Identifying the various utilities mix possible and their respective amount.
750 QH
T You can use a mix of HP
750
and MP steam to fulfill 245 C
245
the heating requirement
900 ΔH = - 150
235
235 C 900
300 Δ H = 600
195
400 195 C 300
185 Δ H = - 100
Process to Process 185 C 400
Heat Transfer
Δ H = 400
145
145 C -0
Δ H = -1400

Steam vapourisation 75 C 1400

1400 Δ H = 200
75
You can choose to generate LP steam instead 35 C 1200
of discharging every thing to cooling water.
Δ H = 200
35 1200 25 C 1000
ΔH
25 1000
1000 QC
14
 HEAT INTEGRATION ENERGY TARGETS – Utility Selection and Targeting
Solution: Alternatively, You can choose to use flue gas for fulfilling the hot utility requirement
especially dealing with very high temperature process e.g., reactor heating. 750 QH
T
Cp (flue gas)
245 o C 750 245 o C
900 ΔH = - 150
235 o C
235 o C 900
300 Δ H = 600
195 o C
400 195 o C 300
185 o C Δ H = - 100
Allowable Stack Temp. Process to Process 185 o C 400
Heat Transfer
Δ H = 400
145 o C
145 o C -0
Cp (steam vapour) Δ H = -1400

75 o C 1400
1400 Δ H = 200
75 o C You can choose to generate superheated
35 o C 1200
LP steam instead of just saturated one.
Δ H = 200
35 o C Cp (feedwater) 25 oC
1000
1200
25 o C 1000 ΔH
1000 QC
15
HEAT INTEGRATION ENERGY TARGETS – Mixed Utilities Targeting

16
 HEAT INTEGRATION ENERGY TARGETS – Utility Selection and Targeting

IN A NUT SHELL
QH
HOT UTILITIES
Temp.

alternatives
ΔTmin

PINCH POINT

QC
COLD UTILITIES
Enthalpy (H)

Composite Curve Problem Table Algorithm and Heat Cascade Diagram

Introducing…

Hot Utility (QHMIN) Further Insight !

T Grand Composite Curve
HP

Can help to identify the possible level MP

of utility to be introduced to avoid Also, enable utility selection and quantification if the options
introduction of it at extreme point ! of utilities are fixed.

LP
CW
Cold Utility (QCMIN) ΔH

17
HEAT INTEGRATION ENERGY TARGETS – Use of Multiple Levels of Steam

18
HEAT INTEGRATION ENERGY TARGETS – Utility Selection and Targeting

With the presence of multiple utilities, the selection for utilities will look more complex.
Furnace Heating

Hot Utility Furnace Heating

HP Steam level No scope for HP

POCKET OF
HEAT RECOVERY
MP Steam Heating
MP Steam level

PINCH

POCKET OF
HEAT RECOVERY
LP Steam level
Raising Low Grand Composite Curve facilitates the selection of the
Temp. Steam
multiple utilities.
Cooling Water
Cooling Water level
Cold Utility ΔH
19
HEAT INTEGRATION ENERGY TARGETS – Utility Selection and Targeting

But there is a systematic way of approaching the mix utility selection and quantification.
T
Hot Utility
HP

MP
Targeting is done from the lowest level utilities and moving up to the
higher one.
The rational is to maximise the cheapest utilities as much as possible
before moving to the more expensive one.
LP

PINCH

Generate LP

Targeting is done from the higher temperature level utilities and

Cooling moving down to the lower one.
Water The rational is to maximise the generation of higher level utilities as
Cold Utility
Refrig. ΔH much as possible before moving down to cooling water and if
necessary, into the refrigeration cooling.

20
HEAT INTEGRATION ENERGY TARGETS – Use of Flue Gas as Hot Utility

21
HEAT INTEGRATION ENERGY TARGETS – Utility Selection and Targeting

Things to note on the use of hot flue gas as heating source.

flame temperature TTFT

mCp
Hot Utility

Tpinch PINCH Case 1 : Limited by the Process Pinch

Tdew

inevitable
losses
Cold Utility
ΔH

Potential recovery 22
HEAT INTEGRATION ENERGY TARGETS – Utility Selection and Targeting

Things to note on the use of hot flue gas as heating source.

flame temperature TTFT

Flue gas line

mCp

Case 2 : Limited by the Process Grand Composite Curve

Tdew
inevitable
losses
Cold Utility
ΔH

Potential recovery
23
HEAT INTEGRATION ENERGY TARGETS – Utility Selection and Targeting

Things to note on the use of hot flue gas as heating source ….

flame temperature TTFT

mCp
Hot Utility

Tdew

Case 3 : Limited by the Flue Gas Stack Temperature

inevitable
losses

Cold Utility
ΔH

24
HEAT INTEGRATION ENERGY TARGETS – Utility Selection and Targeting

What about if hot oil cycle is used ?

Process
Hot Oil Heater

Thot oil

mCp
Hot Utility

Limited by the Process

Hot Oil return temperature

In addition, the hot oil cycle can also be limited by the process pinch but not the
Tpinch PINCH flue stack temperature. Could you draw the grand composite to reflect this?

Cold Utility

ΔH
25
HEAT INTEGRATION ENERGY TARGETS – Use of Hot Oil as Hot Utility

26
HEAT INTEGRATION ENERGY TARGETS – Utility Selection and Targeting

Conclusions

1. Grand Composite curve provides the better insight for deciding multi level utilities.

2. Satisfying hot utility requirement through steam, flue gas or hot oil heating have different
repercussion on the grand composite curve. Similarly for cooling requirement where steam
raising has different repercussion on the grand composite curve compares to cooling water.

3. Selection of utility mix has to be made based on cost which is reflective also on the level.

27
 WORK PROBLEM
Given the heat cascade for a section of a chemical process below;

Minimum Hot Utility = 0.00000 [kW]

Minimum Cold Utility = 10200.0 [kW]

Interval Temperature* Enthalpy

[C] [kW]
---------------------------------------------------------------------
1 367.00000 0.0000000 Pinch
2 366.00000 3500.0000
3 365.00000 7018.3700
4 270.00000 8763.2700
5 170.00000 10400.000
6 140.00000 10334.500
7 70.000000 10054.500
8 60.000000 10254.500
9 30.000000 10200.000
---------------------------------------------------------------------

The ΔTmin for the process is 20 oC.

28
 WORK PROBLEM

i. Plot the Grand Composite Curve

29
 WORK PROBLEM

ii. It is proposed to use steam generation as cold utility for the process.

Assuming that saturated boiler feed water is available and that the steam generated is saturated at a temperature
of 252 oC. Determine the amount of steam generation possible.
Given the latent heat of vaporisation of water is 1706 kJ/kg at 252 oC.

From the grand composite curve, the saturated steam generation is at 252 oC

Given the minimum temp. difference is 20 oC,

the interval temperature for steam generation is 252 + 10 = 262 C.

Marked this on your grand composite curve ...

30
WORK PROBLEM

8900

31
 WORK PROBLEM

ii. It is proposed to use steam generation as cold utility for the process.

Assuming that saturated boiler feed water is available and that the steam generated is saturated at a
temperature of 252 oC. Determine the amount of steam generation possible.
Given the latent heat of vaporisation of water is 1706 kJ/kg at 252 oC.

From the grand composite curve, the amount of heat available for the raising of steam
by the process is 8900 kW.

Therefore the amount of steam that could be raised is :

8900 / Latent heat of vaporisation = 8900 / 1706 = 5.22 kg/sec

32
 WORK PROBLEM

iii. If the steam is superheated to a temperature of 350 oC, calculate how much steam can be generated.

Assume the heat capacity of the superheated steam is 4 kJ/kg.oC.

From the grand composite curve, the saturated steam generation is at 252 oC and it is superheated to
350 oC.

Given the minimum temp. difference is 20 oC,

The interval temperature for steam generation is 252 + 10 = 262 oC.
The interval temperature for the superheated steam target is 360 oC

Marked this on your grand composite curve.

33
 WORK PROBLEM

iii. If the steam is superheated to a temperature of 350 oC, calculate how much steam can be generated then.
Assume the heat capacity of the superheated steam is 4 kJ/kg.oC.

About 8900 kW

34
 WORK PROBLEM

iii. If the steam is superheated to a temperature of 350 oC, calculate how much steam can be generated
then. Assume the heat capacity of the superheated steam is 4 kJ/kg.oC.

Equation used : Q = m( λv + Cp (350 – 252))

= m ( 1706 + 4(98))
= 2098 m

Q is given as = 8900

Therefore m = 8900 / 2098 = 4.24 kg/s.

35
 WORK PROBLEM

iii. If the steam is superheated to a temperature of 350 oC, calculate how much steam can be
generated then. Assume the heat capacity of the superheated steam is 4 kJ/kg.oC.

About 1670 kW
About 8900 kW

36