CEB4313 – PROCESS INTEGRATION

SYNYHESIS OF HEAT EXCHANGER

NETWORK (HEN)

Stream Splitting
Threshold Problems

erniza.rozali@utp.edu.my
STREAM SPLITTING
 Stream Splitting
Above Pinch

PINCH

CP
100° 12
1

100°
2 20

100° 7
3

T > 90 90°
4 15

T > 90 90°
5 30

What do we do?
 Stream Splitting
Above Pinch

PINCH CP

1
100o 12
If the number of hot
100o
2 20
stream is greater than
3 100o 7 the number of cold
streams

90° 15
→ split the cold stream
4

90°
5 30
 Stream Splitting
Above Pinch

Rule:

Above the pinch, NH ≤ NC

• NH = number of hot streams

• NC = number of cold streams
 Stream Splitting
Below Pinch

PINCH

CP
100° T < 100
1 35

100° T < 100

2 60

90°
4 24

90°
5 30

90°
4 20

What do we do?
 Stream Splitting
Below Pinch

PINCH CP
If the number of CP
100
o

cold stream is 35 1 35

greater than a
o
100
60 2 60
number of hot
streams
→ split the hot
stream 90o
24 4 24

90o
30 5 30

90o
20 6 20
 Stream Splitting
Below Pinch

Rule:

Below the pinch, NH ≥ NC

• NH = number of hot streams

• NC = number of cold streams
 Stream Splitting
Example: Below Pinch

NH ≥ NC
The CPH ≥ CPC
rules:
5 7
4
PINCH CP

100° 30°
1 5

100° 40°
2 4

No feasible
90° match! 15° 7
3
 Stream Splitting
Example: Below Pinch

NH ≥ NC
CPH ≥ CPC

5 4
7
4 3
PINCH
50 kW CP Q
100° 40° 30°
1 C1 5 350

100° 43.75° 40° 4 240

2 C2
15 kW

4 300
15°
90° 300 kW 3 225
3 3

225 kW
Split cold stream
 Stream Splitting
Choosing split ratio

What about ?
N H ≥ NC
CPH ≥ CPC

5 3.5
7
There is an
4 3.5
infinite number
or ? of split ratios !
NH ≥ NC
CPH ≥ CPC

5 4.5
7
4 2.5
 Stream Splitting
Choosing split ratio

Save one unit by ticking off two streams at once.

PINCH
CP Q
65 kW
100° 43o 30°
1 C 5 350

100° 40 40° 4
2 240
C

3.8 285
90° 15°
285kW 3
3.2 240

240 kW
𝑄 = 𝐶𝑃 × ∆𝑇
4 100 − 40 = 𝐶𝑃𝐶1 90 − 15
𝐶𝑃𝐶1 = 3.2
 Stream Splitting
Summary

Above Pinch
Stream data
at pinch

Yes Yes
CPH ≤ CPC NH ≤ NC
for Pinch
matches? ?

No
No
Split Cold
Stream

Split Hot
Stream

Place
Matches
 Stream Splitting
Summary

Below Pinch
Stream data
at pinch

Yes Yes
CPH ≥ CPC NH ≥ NC
for Pinch
matches? ?

No
No
Split Hot
Stream

Split Cold
Stream

Place
Matches
 Stream Splitting
Working Session 6
Stream data
Supply Target Heat Capacity
Stream Type Temperature Temperature Flow rate
TT (oC) TT (oC) (KW oC-1)
1 Hot 750 350 45
2 Hot 550 250 40
3 Cold 300 900 43

4 Cold 200 550 20

ΔTmin = 50 ºC

The pinch is at 550 ºC / 500 ºC

QHmin = 9200 QCmin = 6400

Design a network for maximum energy recovery

 Stream Splitting
Working Session 6

Above Below
CP H≤ CP C CPH ≥ CPC
NH ≤ NC N ≥ NC
H

45 43 45 43
20 40 20

Duties above
PINCH
CP the Pinch
750° 550° 350°
45 1 9000kW
550°
250°
40 2

900° 500° 300°

43 3 17200 kW
550° 500° 200°
20 4 1000 kW
 Stream Splitting
Working Session 6

Network Design
CP
CP=40
750o
550o 358.9o 350o
45 1 C
CP=5
400
550o 400o 250o
40 2 C
6000
900o 500o 300o
43 3 H
9200 8000 8600
550o 500o 200o
20 4
1000 6000
THRESHOLD PROBLEMS
 Threshold problems
No integration
T

Steam

Worst case
scenario!

CW

ΔH

When no heat recovery is performed, there is need

for both hot and cold utilities
Threshold problems
Recovering heat
T Steam

ΔTmin

CW

ΔH

ΔTmin = 20ºC ► Process Heat Recovery

 Threshold problems
Reducing ΔTmin: No Hot Utility
T

ΔTmin Reduced

CW

ΔH

ΔTmin = 14ºC ► More Process Heat Recovery

 Threshold problems
Hot End

CW

ΔH
 Threshold problems
Cold End

T
Steam

ΔH
 Threshold problems
How to design the HEN

T ST

ΔH, MW

Treat exactly like a PINCH problem

 HEN Design
Working Session 7

Stream data table

Heat
Supply Target
Stream No Capacity
Temperature Temperature
and Type Flowrate
(°C) (°C)
(kW/°C)
1 Hot 180 80 20
2 Hot 130 40 40
3 Cold 60 100 80
4 Cold 30 120 36

ΔTmin = 7 ºC
The pinch is at 67 ºC / 60 ºC
QHmin = 840 QCmin = 0

Design a Network for Maximum Energy Recovery

 Complete Design
Maximum Energy Recovery Network

CP
180 º 80 º
1 3 20

130 º 67 º 40 º
2 2 1 40

100 º 91.5 º 60 ºC
H1 2 3 80
680 kW 2520 kW

120 º 115.6 º 60 º 30 º
H2 3 1 4 36
160 kW 2000 kW 1080 kW