CPE 633 PROCESS ENGINEERING II

CAPITAL ENERGY TRADE-OFFS

By Siti Shawalliah Idris, AMIChemE

Capital Energy Trade-Offs

The correct setting for DTmin is ECONOMIC
COST

Total

Capital

2 OPT

DTmin

Capital Energy Trade-Offs

Energy cost targets as a function of DTmin

Energy Cost

DTmin

Capital Energy Trade-Offs

But what about capital cost ?

Number of units

Number of heat exchanger units: NMER

NMER =(Sabove -1 ) + (Sbelow -1)
S = number of streams including utilities

Heat Transfer Area Target

Heat transfer area for an enthalpy

interval
T

Concept of calculation:
Construct the composite curves
Put heat exchangers on all streams in each
vertical section of the composite curves
Calculate the area in each section, taking into
account the specific heat transfer coefficients
and correction factors of each stream (U*f)

Network Area

We can set overall area target based on the following equation

Network Area, Amin
T
6

5
4
3
2
1
H

Trading off Energy and Capital Targets

We can track the variation of area target with DTmin

Trading off Energy and Capital Targets

E2

E1

T
DTmin1

DTmin2

Area

1
A1
A2

E1

E2

DTmin

Area and no. of units can be obtained to give variation of capital cost
Area

DTmin

DTmin

Capital cost

DTmin

Total Annual Cost

Capital cost

Energy Cost

DTmin

DTmin

Capital cost
Total
Energy
Capital
DTopt

DTmin

Then we design for DTminOPT (or a resonable value of DTmin

1

250

oC

200 oC

180 oC

230 oC

B
A

80 oC

40 oC

20 oC

140 oC

But, we should still optimise the design

What are the degrees of freedom when optimising the design?

Loop & Path

A loop is a path that begins and

ends at the same point.
Loop
o
1 250 C

200 oC

180 oC
230 oC

H A

B
C

A path is a sequence of distinct

lines that are connected to each
other.

40 oC

-Y (W)
1 250

80 oC

20 oC
140 oC

3
4

oC

Path

B
C

200 oC

180 oC

230 oC

B
A

+Y (W) -Y (W)

40 oC

80 oC

D
C

+Y (W)

20 oC

140 oC

3
4

Loop & Path

Heat duties can be changed within a loop without changing the utility consumption
Loop

-U (W)
1

250

oC

180 oC

230 oC

200 oC

B
A

+U (W)

-U (W)

80 oC

E
+U (W)

40 oC

20 oC

140 oC

This changes both loads and temperature differences

Another Loop
-V (W)
1

250 oC

Loop

+V (W)

B
+V (W)

200 oC

180 oC

230

A
-V (W)

-V (W)

80 oC

+V (W)
oC

40 oC

-V (W)

20 oC

140 oC

+V (W)

Changes both loads and temperature differences

Heat Duties can be changed alonh a utility path to change the utility consumption
-Y (W)
1

250 oC

180 oC

230 oC

+Y (W)

200 oC

A
-Y (W)

+Y (W)

Utility

80 oC

40 oC

20 oC

140 oC

There are other utility paths in this problem

-Y (W)
o
250 C

200 oC

180 oC

230 oC

Utilit
y

B
A

+Y (W) -Y (W)

40 oC
1
80 oC

D
C

+Y (W)

20 oC

140 oC

-X (W) +X (W)
250 oC

-X (W)

Utility

200 oC

180 oC

-X (W)

+X (W) -X (W)

40 oC

80
oC

+X (W)
230 oC

+X (W)

20 oC

140
oC

250 oC

-Z (W)
2

200

oC

180 oC

230 oC

+Z (W)

-Z (W)

Utility
Path

C
-Z(W)

40

250 oC

-U (W)
80
oC

+Z (W) -Z (W)

20 oC

200 oC

180 oC

230 oC

+U (W)

40 oC

+U (W)

80
oC

-U (W)
140
oC

+U (W)

Utility
Path

-U (W)

oC

+Z (W)

+Z (W)

+U (W)

-U(W)

20 oC

140
oC

What is optimum ?
U, V, X,Y, Z must be varied simultaneously to minimise cost

MULTIVARIATE OPTIMISATION

ALSO, for designs with stream splits

500 oC

T>160oC
500 oC

480 oC

460 oC

300 oC

CP

0.94

180o

1.5

300o

2.0

350o

CP
3

T>180oC
180 oC

160 oC

Branch flowrates are additional degrees of freedom

CP

2.06

354o

1.5

300o

1.0

200o

Summary

Energy and capital cost targets can be set prior to design

Energy and capital cost can be traded off ahead of design

Network designs can be optimised by exploiting the degrees of

freedom in loops, utility paths and stream splits

Summary

Some problems exhibit a threshold only hot or cold utility required.

True threshold problems have large temperature driving force and no
pinch.
Most threshold problems turn out to be pinched problems after
multiple utilities used

Thank you for your attention

Working Example
Capital Energy Trade-offs

Maximum Energy Recovery Design

Identify the degrees of freedom for network optimisation
HP
100 oC

1
160 oC

100 oC

2425

B
75 oC

3
140 oC

80 oC

H
150

oC

7050

80 oC 6

B
16000

4500

DTmin = 20oC

1925

90 oC

C
4330

C
79 oC

2100

42 oC

D
16670

40 oC
25 oC
25 oC

4
5

100 oC

1
160 oC

100 oC

2425

B
75 oC

3
140

oC

80 oC

H
2100

150 oC

7050

4500

80 oC 6

B
16000

1925

90 oC

C
4330

C
79 oC

42 oC

D
16670

40 oC
25 oC
25 oC

4
5

Solution
Loop
HP
100 oC

1
160 oC

100 oC

2425

B
75 oC

3
140 oC

80 oC

150

oC

7050

A
4500

80 oC 6

B
16000

1925

90 oC

C
4330

C
79 oC

2100

42 oC

D
16670

40 oC
25 oC
25 oC

4
5

Loop

100 oC

1
160 oC

100 oC

2425

B
75 oC

3
140 oC

80 oC

150

oC

7050

A
4500

80 oC 6

B
16000

1925

90 oC

C
4330

C
79 oC

2100

42 oC

D
16670

40 oC
25 oC
25 oC

4
5

Utility path 1

100 oC

1
160 oC

100 oC

2425

B
75 oC

3
140 oC
Utility path 2

150

oC

80 oC

H
H

7050

A
4500

80 oC 6

B
16000

1925

90 oC

C
4330

C
79 oC

2100

42 oC

D
16670

40 oC
25 oC
25 oC

4
5