Heat Exchanger

Network Synthesis
ChE 141
1st sem AY 1718
Outline
• Process Integration Overview
• Pinch Technology Overview
• MERs
• Problem Table Algorithm
• Setting Practical Targets
• Pinch Design Methodology
• Heat Exchanger Network Synthesis
So far…

A
C
B

Input-Output Synthesis ● Reactor Synthesis

Separation Synthesis ● Heat Exchanger Network
So far…

A
H C
B
C

Input-Output Synthesis ● Reactor Synthesis

Separation Synthesis ● Heat Exchanger Network
So far…

A
H C
B
C

Input-Output Synthesis ● Reactor Synthesis

Separation Synthesis ● Heat Exchanger Network
Now…

A C

C
B

Input-Output Synthesis ● Reactor Synthesis

Separation Synthesis ● Heat Exchanger Network
Process Integration
All improvements made to process systems, their
constituent unit operations and their interactions
to maximize the effective use of energy, water
and raw materials (NRCan, 2003)
Pinch Analysis as a PI Approach

Target Setting Network Design

Goal: Match individual demand for a commodity with a
suitable supply
Minimum Energy Requirements/
Maximum Energy Recovery

Hot composite Cold composite

curve curve
heat available heat demand
Constructing Composite Curves
• Extract process data from your HMB
Constructing Composite Curves
• Plot each stream in a T vs Q plot
• Combine stream portions present in the same
temp interval by adding Q
Establishing MERs
• Move the cold CC towards hot CC until minimum
vertical approach is reached

Significance of ∆Tmin?
Significance of the pinch point?
How to establish MERs if there are a lot of streams?
Pinch Point
Divides system into two
independent zones
• hot utility only zone
• cold utility only zone

Rules for practical

network design
• No external heating
below the pinch
• No external cooling
above the pinch
• No heat transfer across
the pinch
Typical ∆Tmin
• Based on industry experience
Problem Table Algorithm
• Numerical approach for establishing MERs when there
are a lot of streams
Problem Table Algorithm
• Step 1: Set-up shifted T intervals using stream supply and
target T by subtracting 0.5∆Tmin from hot streams and
adding 0.5∆Tmin to cold streams.
Stream Stream Cp
Actual Temp Shifted Temp
No. Type (kW/℃)
Ts (℃) Tt (℃) Ts (℃) Tt (℃)
1 Hot 20 200 100 195 95

2 Hot 40 150 60 145 55

3 Cold 80 80 120 85 125

4 Cold 15 50 220 55 225

∆Tmin = 10oC
Problem Table Algorithm
• Step 2: Perform an energy balance on each interval to
determine the surplus/deficit heating duty
Cp: 20 Cp: 40 Cp: 80 Cp: 15
225

1 195 1
2 2
145 H i  [ C p ,c  C p , h ]i * Ti
3 125
j j

4 95
5 3
85
6 55 4
Problem Table Algorithm
• Step 2: Perform an energy balance on each interval to
determine the surplus/deficit heating duty
Net Cp
Interval ∆T (℃) ∆H (kW)
(kW/℃)
1 30 15 450 Deficit
2 50 -5 -250 Surplus
3 20 -45 -900 Surplus
4 30 35 1050 Deficit
5 10 55 550 Deficit
6 30 -25 -750 Surplus
Problem Table Algorithm
• Step 3: Cascade any surplus heat available down the
temperature scale from one interval to the next. Note
that heat cannot be transferred up the temperature
scale.
Interval ∆H (kW) ∆H out Interval ∆H (kW) ∆H net
0 900

1 450 -450 1 450 450

2 -250 -200 2 -250 700

3 -900 700 3 -900 1600

4 1050 -350 4 1050 550

5 550 -900 5 550 0

6 -750 -150 6 -750 750

Problem Table Algorithm
• Step 3: Cascade any surplus heat available down the
temperature scale from one interval to the next. Note
that heat cannot be transferred up the temperature
scale.
Interval ∆H (kW) ∆H net
900 Minimum hot utility req’t
1 450 450
Which utility should be used
2 -250 700 to meet requirements?
3 -900 1600

4 1050 550
T Pinch = Shifted Temp – 0.5∆Tmin
5 550 0 90oC and 80oC
6 -750 750 Minimum cold utility req’t
Target Setting
• MERs Targeting
• Minimum Energy Cost Targeting
• No. of Units Targeting
• Area Targeting
• Heat Exchanger Network Capital Cost Targeting

Targets are used to set direction of HEx

network design
MERs Targeting
• Goal is to meet the minimum utility requirement

Interval ∆H (kW) ∆H net

900

1 450 450

2 -250 700

3 -900 1600

4 1050 550

5 550 0

6 -750 750
Minimum Energy Cost Targeting
• Goal is to maximize use of cheaper utilities and minimize use of
more expensive utilities.
• Established using the grand composite curve (GCC)
• To create GCC, simply plot the shifted temp against the ∆H net

Interval ∆H (kW) ∆H net 215

195
900

shifted temp
175

1 450 450 155

2 -250 700 135

115
3 -900 1600
95

4 1050 550 75

5 550 0 55
0 500 1000 1500 2000

6 -750 750 dH net

Minimum Energy Cost Targeting
• Goal is to maximize use of cheaper utilities and minimize use of
more expensive utilities.
• Established using the grand composite curve (GCC)
• To create GCC, simply plot the shifted temp against the ∆H net

235 HPS (249oC)

Utility Tsupply Treturn
215

shifted temp
HPS 254 254 195
175

MPS 185 185 155 LPS (148oC)

135
LPS 153 153 115
95
CW 32 49 75
55
CW(54oC, 37oC)
UtilityCost   QU CU 0 500 1000
dH net
1500 2000

U
+slope : cold stream
-slope : hot streams
Area Targeting
• CC are divided into set of adjoining intervals such that within
each interval, hot and cold CC do not change slope

Q=UA(LMTD)
Number of Units Targeting
• Since there should be no heat transfer across the pinch, unit
counts above and below the pinch can be counted separately.
HEN Cap Cost Targeting
• Based on minimum number of units [a=16000, b=3200, c=0.7,
Installation factor = 3.5]
∆Tmin Optimization
• Setting the ∆Tmin involves balancing trade offs between capital
cost and energy savings. Capital cost is annualized.
Pinch Design Method
Feasibility Criteria
• Stream Population Criteria
• CP Inequality Criteria
• CP difference criteria
• CP table
• Stream tick off rule
• Remaining problem analysis
• Cyclic matching
• Rule of CP ratio

Essential matches can be established

by using three criteria
Stream Population Criterion
• Used to ensure that the population of hot and cold streams has
will allow an arrangement of exchangers compatible with
minimum utility usage.
• Above pinch point

N cold  N hot
• Below pinch point

N cold  N hot
Cp Inequality Criterion
• Used as a guide to determine which streams to match
• Above pinch point

C p ,cold  C p ,hot
• Below pinch point

C p ,cold  C p ,hot
Cp Difference Criterion
• Used to ensure that all matches would
meet Cp Inequality Criterion
• Above pinch point
Cp, diff  Cp, c  Cp, h
• Below pinch point

Cp, diff  Cp, h  Cp, c

• Condition

 Cp, diff  overallCp, diff

Cp Table
• Systematic way to determine compliance on other criteria
Stream Tick Off Rule
• Used to determine how much heat would be exchanged once a
stream match is established based on the goal of minimizing the
number of units in the HEx network.
• To minimize the number of HEx units, one of the streams in the
match has to achieve its target temperature. The associated duty
to the temperature change would be the duty of the match and
would be used to calculate the outlet temperature of the other
stream.
• Once a stream’s temperature change is completely achieved, it
is ticked off.
Pinch Design Method
Stream Splitting

Involves dividing a cold or hot stream into two subsets so that

the Cp values would comply with the Cp inequality rule
Stream Splitting
Stream Splitting
Stream Splitting
Stream Matching
• Match streams using the Cp Table approach.
• Once all streams are matched, use utilities to
meet remaining heating/cooling requirements.
• Adjust design to meet target(s)
• For now, set MERs as the primary target
Stream Matching: Grid Diagram
CP:20 90oC
200oC 100oC
CP:40
150oC 60oC
CP:80
120oC 80oC
CP:15
220oC 50oC
Above pinch Below pinch
80oC
Stream Matching: Below Pinch
90oC 40

15

No rules violated
CP: 40
78.75oC
60oC 2

From the tick off rule,

we tick off 4 thus
setting the duty at
CP: 15 450 kW and the
outlet temp of 2 at
4
450 kW
50oC 78.75oC

Below pinch
80oC
Stream Matching: Below Pinch
90oC

A cooler which uses

CP: 40 cooling water can
78.75oC be used to remove
60oC 2 the remaining heat
750 kW from 2.

CP: 15

4
450 kW
50oC
Below pinch
80oC
Stream Matching: Above Pinch
CP:20 90oC
20 80

200oC 100oC 1
40 15

CP:40 2-4 match violates

Cp inequality rule.
150oC 2

CP:80 20 80

3
120oC 40 15

1-4 match violates

CP:15 Cp inequality rule.
4
220oC
Since there are no
Above pinch feasible match,
80oC split a hot stream
Stream Matching: Above Pinch
CP:20 90oC
20 80

200oC 100oC 1

CP:40 40- 15

CP:40-
150oC 2 Nc<Nh

CP:80 CP:
3
120oC Splitting violated
stream population
CP:15 criterion. Split a
4 cold stream.
220oC
Above pinch
80oC
Stream Matching: Above Pinch
CP:20 90oC
20 80-

200oC 100oC 1

40- 15

CP:40-
150oC 2 Stream population
criterion satisfied.
CP:
CP:80-
120oC 3 Set and values
so that the Cp
CP:15 CP: inequality criterion
4 will be satisfied for
220oC all matches
Above pinch = 50; = 15
80oC
Stream Matching: Above Pinch
CP:20 90oC
20 30

200oC 100oC 1
15 50

25 15

CP:25 102oC
150oC 2 All matches satisfy
900 kW stream population
and Cp inequality
CP:15
criteria
CP:30
120oC 3
1200 kW The remaining
CP:15 CP:50 temperature
2000 kW
4 changes can be
220oC provided by
140oC
heating/cooling
Above pinch with utilities
80oC
Stream Matching: Above Pinch
CP:20 90oC
20 30

200oC 100oC 1
15 50

25 15

CP:25 102oC 300 kW

150oC 2 All matches satisfy
900 kW stream population
and Cp inequality
CP:15
criteria
CP:30
120oC 3
1200 kW The remaining
CP:15 temperature
2000 kW CP:50
changes can be
4
220oC achieved by
o
1200 kW 140 C heating/cooling
Above pinch with utilities
80oC
Stream Matching: Overall
CP:20 90oC
200oC 100oC 1

CP: 40
102oC 300 kW 78.75oC
CP:25
150oC 2 60oC
900 kW
750 kW
CP:15
CP:30
120oC 3
1200 kW
CP:15 CP:50 CP: 15
2000 kW
4
220oC 450 kW
50oC
o
1200 kW 140 C
Above pinch Below pinch
80oC
Overall HEx Network
Comparison of MERs

Energy No HEx
Minimum Actual
Requirement Network

Cooling (kW) 750 1050 5600

Heating (kW) 900 1200 5750

Proceeding Further
• If the design based on the MER target is acceptable,
then set the configuration as the final HEx network.
• For further optimization, if the MER target is already
maxed out*, consider changing configuration to improve
network design based on another target (e.g. utility cost,
HEx network capital cost, etc.).
• Improve design based on a single target a time!

*can’t be improved despite adjustments

Possible Compromise: Non-Pinch
Matches
• Away from the pinch, there is more flexibility to make matches so
the Cp inequality rule can be relaxed.
• Smaller ∆T might result to larger HEx area
• Apply your best judgment in establishing matches. Try to observe
the ∆Tmin so that the HEx area would not be too large.
Alternative Matching
CP:20 90oC
117.5oC 20 80

200oC 100oC 1
40 15

CP:40 Although a match

between 1 and 4
150oC 2
violates the Cp
inequality rule, we
CP:80 can consider
relaxing the
120oC 3 restrictions since the
∆T of 4 is large
CP:15
We can set ∆T at the
4
220oC other end to be equal
190oC to ∆Tmin which would
Above pinch result to a duty of 1650
80oC kW
Alternative Matching
CP:20 350 kW 90oC We can then proceed
117.5oC
200oC 100oC 1 to matching using
Pinch Methodology
CP:40
20 80
150oC 2
40 15

CP:80 We can match 1

120oC 84.38oC
3 and 3 to tick off 1

CP:15
4
220oC
190oC
Above pinch
80oC
Alternative Matching
CP:20 350 kW 90oC
117.5oC 80
200oC 100oC 1
40 15

CP:40 Cp inequality and

2400 kW
stream population
150oC 2
criteria are satisfied

CP:80 A match between 2

and 3 can be set to
120oC 3
tick off 2
114.4oC 84.38oC
CP:15
4
220oC
190oC

Above pinch
80oC
Alternative Matching
CP:20 350 kW 90oC
117.5oC 80
200oC 100oC 1
15

CP:40 Cp inequality and

2400 kW
stream population
150oC 2
criteria are satisfied

CP:80 The remaining cold

streams can then be
120oC 3
heated with steam
450 kW 114.4oC 84.38oC
utility
CP:15
4
220oC
450 kW 190oC
Above pinch
80oC
Alternative Network
CP:20 350 kW 90oC
117.5oC
200oC 100oC 1

CP:40 CP: 40
2400 kW 78.75oC
150oC 2 60oC
750 kW
CP:80
120oC 3
450 kW 114.4oC 84.38oC
CP:15 CP: 15

4
220oC 450 kW
50oC
450 kW 190oC
Above pinch Below pinch
80oC
Alternative HEx Network
Comparison of MERs
Actual (with
Energy No HEx
Minimum Non Pinch
Requirement Network
Matching)

Cooling (kW) 750 750 5600

Heating (kW) 900 900 5750

Questions?