Heat Exchanger Network

Synthesis
(HENS/)

L1
 Hydro dealkylation of
toluene Purg
e
328
311 895 K
K
Hydrog K 895
K 895 311
en Reactor K K
feed 295 895
Tolue
K 895 K
ne 347
K K
feed
391

Stabilizer
K
Tolue 466

Benzene
ne 895

Column
K K
recyc
le
295
Column
Toluene

540
K
K Benze
ne
Produc
Diphe t
HENS
1. What is the minimum cooling and heating
requirements?
2. Is it possible to specify this detail without
any Heat exchang network?
3. Is it possible to specify minimum number
of HEXs for attaining minimum energy
requirements?
4. Recall the typical number of HEXs in the
ethanol flowsheet
5. We shall understand this using a very
simple example
 A simple example
Stream Conditio Q
No. n available

1 Hot 1000 250 20 130

2 Hot 4000 200 100 400

3 Cold 3000 90 150 -180

4 Cold 6000 130 190 -360

-10
 Two streams need to be heated
 Two streams need to be cooled
 H1 stream has to reject heat at 130 kBtu/hr
 H2 stream has to reject heat at 400 kBtu/hr
 A simple example

Stream Conditio Q
No. n available

1 Hot 1000 250 20 130

2 Hot 4000 200 100 400

3 Cold 3000 90 150 -180

4 Cold 6000 130 190 -360

-10
 C1 stream has to gain heat at 180 kBtu/hr
 C2 stream has to gain heat at 360 kBtu/hr
 So, 10 kBtu/hr is to be supplied if there is no
restriction on temperature driving force
A simple example
 This calculation is based on first law of
thermodynamics analysis
 However, the first law analysis neglects the
heat exchange feasibility
 In other words, the 2nd law must be satisfied!
 2nd law can be satisfied using temperature
interval concept
 Lets say we want to design HEX for 10 oF
approach temperature
 Generate the temperature plots as shown
below for each stream
 Temperature
Intervals
Stream Condition Q
No.
1 Hot 1000 250 20 130
2 Hot 4000 200 100 400
3 Cold 3000 90 150 -180
4 Cold 6000 130 190 -360

 Establish intervals as
shown below
H1
25 24
0 0

H2 20 19
0 0
15 14 C2
0 0

10 90 C1
 In each interval, heat
0 transfer is guranteed [2nd
Law]
Available Heat in an interval
 
𝑄𝑖=[ ∑ ( 𝐹𝐶 𝑝 )h𝑜𝑡 ,𝑖 − ∑ ( 𝐹 𝐶 𝑝 )𝑐𝑜𝑙𝑑,𝑖 ] ∆𝑇 𝑖
 
-40*

 This can be visualized from the following

diagram
25 24
H1 0 0

H2 20 19
0 0
15 14 C2
0 0

10 90 C1
0
 How much is the summation of all heats? -10 !
Cascade Diagram
The limitation of the first law can be
overcome by the cascade diagram
Transfer the heat from hot to cold stream in
any interval
Any excess heat can be transferred to a
lower interval stream
250 24
 If required, heat can
50be supplied from a hot
0
utility
-
20 40 19
Utility

0 0

Utility
Hot

Cold
80
15 40 14
0 0
20
10 90
0
Cascade Diagram
 All the required heat (40+80=120) can be supplied
from hot utility
 All the heat rejection (50+40+20=110) can be
done to the cold utility
 What is the difference of the two? Relate this with
the 1st law analysis
250 24
 Is this a good alternative?
50 Why? 0

-
20 40 19
Utility

0 0

Utility
Hot

Cold
80
15 40 14
0 0
20
10 90
0
Pinch
temperature
 We can transfer the heat from the higher to lower
interval
 Do we satisfy the 2nd law? How?
 Minimum heating requirement 70 kBtu/h
 Minimum cooling requirement 60 kBtu/h
 What is the difference between the two?
 There is no energy transfer between 3rd and 4th
interval!
 This is the pinch temperature (140 oF for hot and
25 24
130 oF for the
0 cold or 135 o
F the5 average) 0
0 5
-40 0
20 1 19
7
Utility

Utility
0 - 0 0

Cold
0
Hot

15 80
40 14
0 6 0
2 0
10 90
0
Pinch temperature
This pinch T and minimum heating and
cooling requirements depend on the
approach T (10 oF)
What if we change this approach
temperature
Need to reconstruct the cascade diagram
It can be easier to see this from T-enthalpy
diagram
Lets plot T-Q diagram for cold and hot
streams
 T-Enthalpy
Diagram
Thot <
Tcold
Tcold Q-COLD
90 0 250 (2 oC)
130 120
150 300
190 540 200
T, oF
Thot Q-HOT
100 0 150
120 80
140 180 10 kBtu/
160 280 100
200 480 Hot Composite Curve
250 530
Cold Composite Curve
50
0 200 400 600
Enthalpy, Q, kBtu/hr
Is it a feasible Heat transfer scenario? Why?
 T-Enthalpy Diagram with
Qcold=20
Thot > Tcold
Tcold Q-COLD
90 20 (4 oF)
130 140
150 320 Qcold=30
190 560 250

200
T, oF

Thot Q-HOT
100 0 150
120 80
140 180
160 280 100
200 480 Hot Composite Curve
250 530 Cold Composite Curve
50
0 200 400 600
Enthalpy, Q, kBtu/hr 40 kBtu/hr
To be
30 kBtu/hr
rejected: 30
 T-Enthalpy Diagram with
Qcold=60
Tcold
90
Q-COLD
60
Thot >
130 180 Tcold
150 360
190 600 Qcold=60 (10 oF)
250

Thot Q-HOT
100 0 200
120 80
T, oF

140 180
160 280 150
200 480
250 530
100
Hot Composite Curve
Cold Composite Curve
50
0 200 400 600
Enthalpy, Q, kBtu/hr 70 kBtu/h
To be
60 kBtu/hr
rejected: 60
 Grand Composite Curve
(GCC)
235

215

195

175

T, oF
155

135

115

95

75
0 10 20 30 40 50 60 70 80 90 100 110 120 130
Q, kBtu/hr
Q, Btu/h 130 400 -180 -360
FCp,
kBtu/(hr.F) 1 4 3 6
Net heat
flow
to the
system
=Qhot-
Qhot, kBtu/h T-HOT T-AVG T-COLD Qcold Qcold Qnet T-AVG
H1 H2 250 245 240 C1 C2 70 245
50 200 195 190 0 70 120 195
200 160 155 150 240 120 80 155
100 140 135 130 180 80 0 135
100 120 115 110 60 -40 40 115
80 100 95 90 60 -20 60 95
Calculation for the GCC
 Start at the pinch point (135 oF) with Q=0
ABOVE PINCH
In the next interval (135-155 oF), find =80
In the next interval (155-195), = 40,
(cumulative 120)
In the next interval (195-245), = -50,
(cumulative 70)
BELOW PINCH
Interval (115-135), = 40, (cumulative 40)
Interval (95-115), = 20, (cumulative 60)
Grand Composite Curve
(GCC)
235
215
195
175

T, oF 155
135
115
95
75
0 10 20 30 40 50 60 70 80 90 100 110 120 130
Q, kBtu/hr

 Minimum heating requirement, =70 kBtu/hr

Minimum cooling requirement, =60 kBtu/hr
GCC is more useful for profile matching during
heat integration
Any additional heat requires equal amount of
 Industrial
Practice
Minimum heat in
= 70 25
50
24
0 𝑄 0
  𝐸 50
-40
20 10+𝑄 19
Proce Net = 0 7   𝐸
0

Utility

Utility
- 𝑄
  𝐸
ss -10 0

Cold
Hot
15 80 14
1
4
0 40+𝑄 4
0
  𝐸 0
2
Minimum heat 10 0
60+𝑄
  𝐸 9
0 0
out = 60heat in = 70
 Minimum
+ Important Thumb Rules
Do not transfer heat across
Proce Net = the pinch
ss -10 Add heat only above the

 Minimum
pinch
heat out =
60 + Remove heat only below the
 Double Penalty

Calculation of minimum heating requirement is

very simple
However, significant energy saving can be
made
30-50% energy saving is possible!
 Multiple
Utilities
 Do we always require only one cold
utility?
This can be a better economical option
Thus, steam at can be used as one cold
utility
And cooling water as another cold utility
350 340
50
 𝑄 𝐸
Hot Utility

-40 50

Steam
300 290
10
7
0 -80
250 40 24
40 0
40+𝑄
  𝐸 20 CW 19
200 20
0
 Multiple Utilities

Thus, there is no heat transfer across the

bottom two intervals!
We added another pinch! This is a utility pinch
Lets see the T-H diagram

Thumb Rules
Always add heat at the lowest possible
temperature relative to the process pinch
Always remove heat at the highest possible
temperature relative to the process pinch
 Phase
Change
The pinch analysis was carried out for constant
FCp! Why?
What if there is phase change?
We use fictitious FCp assuming 1 oF interval
For the jth stream,  𝐯𝐚𝐩𝐨𝐫

 𝐅 𝐟 𝐂 𝐩𝐟 ( 𝐈 )=𝐅 ∆ 𝐇 𝐞
F 

F 

F 

 𝐥𝐢𝐪𝐮𝐢𝐝
 Limitations of the procedure

Fcp values are known for all streams

Inlet and outlet temperatures of all streams
are known
However, Process flows are obtained from the
design variables
Such design variables (conversion, purge
compositions, molar ratios of the reactants
etc.) are obtained from optimization
This optimization involves recycle cost
calculation etc.
This in turn depends on heat exchanger
Focus on No. of exchangers
We designed HENS for minimum cooling
and heating
Lets see now for minimum number of
exchangers now
Lets first see the number of exchangers
based on 1st law Hot Strea Strea
Source Utilit
Ignore the minimum
s approach
m1 temperature
m2
y 130 400
for the time being!70
11 34
7 2 6
0 0
0 0 0
Strea Strea Cold
Sin Utility
m3 m4
ks 60
400 360
No. of exchangers – 1st Law
Five heat exchangers!
Heat loads balance exactly (1st law)

  𝐍𝐮𝐦𝐛𝐞𝐫 𝐨𝐟 = 𝐍𝐮𝐦𝐛𝐞𝐫 𝐨𝐟 + 𝐍𝐮𝐦𝐛𝐞𝐫 𝐨𝐟 − 𝟏

( 𝐄𝐱𝐜𝐡𝐚𝐧𝐠𝐞𝐫𝐬) ( 𝐒𝐭𝐫𝐞𝐚𝐦𝐬 )( 𝐔𝐭𝐢𝐥𝐢𝐭𝐢𝐞𝐬 )

Hot Strea
Source Strea
Utilit m1
s m2
y 130 400
70
11 34
7 2 6
0 0
0 0 0
Strea Strea Cold
Sin Utility
m3 m4
ks 60
400 360
 Independent Problems – 1st
Law
This equation is now always correct
See the following option satisfying 1 st law
Utility is more here!
How many heat exchangers?
2 independent problems! Hot Strea
Source Strea
Utilit m1
s m2
y 130 400
230 13
230
0 18
0 220

Strea Strea Cold

Sin Utility
m3 m4
ks 220
180 360

  𝐍𝐮𝐦𝐛𝐞𝐫 𝐨𝐟 = 𝐍𝐮𝐦𝐛𝐞𝐫 𝐨𝐟 + 𝐍𝐮𝐦𝐛𝐞𝐫 𝐨𝐟 − 𝐍𝐮𝐦𝐛𝐞𝐫 𝐨𝐟

( 𝐄𝐱𝐜𝐡𝐚𝐧𝐠𝐞𝐫𝐬) ( 𝐒𝐭𝐫𝐞𝐚𝐦𝐬 )( 𝐔𝐭𝐢𝐥𝐢𝐭𝐢𝐞𝐬 ) ( 𝐢𝐧𝐝𝐞𝐩𝐞𝐧𝐝𝐞𝐧𝐭 𝐏𝐫𝐨𝐛𝐥𝐞𝐦𝐬 )
Loops – 1st Law
How about the following alternative for any
value of QEHot
Source Strea Strea
Utilit m1
s m2
y 130 400
230  𝑄 𝐸 34
 70-
 
110+  
20- 0
60

Strea Strea Cold

Sin Utility
m3 m4
ks 60
180 360
Note a loop here
Each loop adds an extra heat exchanger

𝐍𝐮𝐦𝐛𝐞𝐫 𝐨𝐟 = 𝐍𝐮𝐦𝐛𝐞𝐫 𝐨𝐟 + 𝐍𝐮𝐦𝐛𝐞𝐫 𝐨𝐟 − 𝐍𝐮𝐦𝐛𝐞𝐫 𝐨𝐟

(  𝐄𝐱𝐜𝐡𝐚𝐧𝐠𝐞𝐫𝐬 ) ( 𝐒𝐭𝐫𝐞𝐚𝐦𝐬 ) ( 𝐔𝐭𝐢𝐥𝐢𝐭𝐢𝐞𝐬 ) (𝐢𝐧𝐝𝐞𝐩𝐞𝐧𝐝𝐞𝐧𝐭 𝐏𝐫𝐨𝐛𝐥𝐞𝐦𝐬 )
 Effect of Pinch – 2nd Law
We had observed one pinch in our problem
Above the pinch we only supply the heat
from utility
Below the pinch we only extract the heat to
the utility  
= 4+1-1=
For minimum heating and cooling,
25 24
0 0
20 19
0 0

14 15 14 13
0 0 0 0

10 90 Below
 
0 = 3+1-1=
Effect of Pinch – 2nd Law
For minimum heating and cooling,
1st law requires only 5 HEXs
2nd law requires 7 HEXs
Thus, for minimum energy requirement,
there must be two loops that cross the pinch
If we are willing to transfer some energy
across the pinch, we can eliminate 2
exchangers!
Effect of Pinch – 2nd Law
For minimum heating and cooling,
1st law requires only 5 HEXs
2nd law requires 7 HEXs
Thus, for minimum energy requirement,
there must be two loops that cross the pinch
If we are willing to transfer some energy
across the pinch, we can eliminate 2
exchangers!
Trade off, Min energy requirement Vs Min
number of exchangers
Operating cost Vs. Fixed cost
Heat Transfer Area Estimate
We found minimum heating and cooling
requirements without fixing the HENS!
This finding can help us to estimate the
amount and cost of the utility as well!
It will be great if we can estimate capital
cost without designing a HENS as before!
 This can be estimated using a technique
proposed by Townsend and Linhoff
 Lets look at the T-H diagram again and add a
vertical line when there is a change of slope!
Heat Transfer Area Estimate
Heat Transfer Area Estimate
 We can find the heat duty for each interval
We can also note the endpoint
temperatures in this interval
If there is only one cold and hot process
 𝟏 𝟏 𝟏
stream in this interval,
= +
𝐔 𝐡𝐢 𝐡𝟎

Here, hi and ho also include the fouling

factor
HT Area,
Heat Transfer Area Estimate
 What is the Area expression for multiple streams?
 Suppose there are two hot steams (1 & 2) and two
cold streams (3 & 4) in an interval
 There are two possible matches: (a) 1 with 3 & 2
with 4 OR (b) 1 with 4 & 2 with 3
1/ h1 ∆  𝑇 2
 Lets see the Area calculation for both the  options

  1 =1 +1 1 =1 + 1 ∆  𝑇 1
𝑈 𝑎 1 h1 h 3 𝑈 𝑎 2 h 2 h 4 1/
  h3

  1/
  h2
=

1/
  h4
 Heat Transfer Area Estimate
(a) 1 with 3 & 2 with 4 (b) 1 with 4 & 2 with 3

1/
  h1 1/
  h2 1/
  h1
1/
  h2

1/
  h3 1/
  h4 1/
  h4
1/
  h3

  1 =1 +1 1 =1 + 1   1 =1 +1 1 =1 +1
𝑈 𝑎 1 h1 h3 𝑈 𝑎 2 h2 h 4 𝑈 𝑏 1 h 1 h4 𝑈 𝑏 2 h 2 h 3

 𝐴𝑟𝑎 =𝐴 𝑎 1 + 𝐴𝑎 2 = 𝑄 𝑄 𝑄 𝑄
+  𝐴𝑡𝑜𝑡 =𝐴 𝑏 1 + 𝐴𝑏 2 = +
∆ 𝑇 𝐿𝑀 𝑈 𝑎 1 ∆ 𝑇 𝐿𝑀 𝑈 𝑎 2 ∆ 𝑇 𝐿𝑀 𝑈 𝑏1 ∆ 𝑇 𝐿𝑀 𝑈 𝑏 2

  =
  =

  h𝑜𝑖 𝑐𝑜𝑙𝑑
𝑄 1 1
In general, 𝐴=
∆ 𝑇 𝐿𝑀 ( 𝑖 𝑖 𝑗 𝑗
)
∑ h +∑ h A= sum of A for all interva
Total
 Heat Transfer Area Estimate
  h𝑜𝑖 𝑐𝑜𝑙𝑑
𝑄 1 1
In general, 𝐴=
∆ 𝑇 𝐿𝑀 ( ∑h ∑h
𝑖 𝑖
+
𝑗 𝑗
)
• Total A= sum of A for all intervals
• Note: This is a shortcut calculation
procedure to estimate the area
• This is particularly useful for the effect
of process flows on the HEX network
• Once the optimum flows are computed,
detailed HEX design is required
 Design of Min-Energy HEN
• We will design the HEN for above the
pinch and below the pinch, separately,
why?
• Design above the pinch
• Calculate the heat loads between inlet
or outlet and the pinch point
 Above Pinch:
temperature for each stream
Below Pinch:
• Stream 1:

• For the reaming streams, see the figure

in next slide
 Heat Loads for all the
streams
Strea 1 2 3 4
m 100 400 250 300 600
250
0 0 0 0
 
=110+240-60-360=70
Q=110

200 190
Q=240
Q=360

Q=60
150 140
140 130
Q=20

Q=160 Q=120

100 90  
=20+160-
120=60
 Feasible Matches
Lets see the matching of: Stream 1 with
Stream 3
Maximum heat transfer = min of the two, FC Str
p m
which is 60 3 1
Approach T= 10 oF at the pinch 1 3
Lets see this value at the
Strea 1 other end 3
  m 
F 10 300
Tin of stream 1, 00 25 24 0
0 0
Is it a feasible
Q=11 20 19
Match? 0 0 0
130 150

Q=6
15 14
14 0 13
140 200 0 0
0 0
Feasible Matches
Lets see the matching of: Stream 2 with
Stream 3
This
 Is it atime, Tin of stream130
feasible 1, 150 FC Str
p m
Match? Why?
3 1
Whats the approach
155 1 3
TSuch
at the violation always 140
other end?
occur above pinch if,
2 3
[FCp]C > [FCp]H, 400 30
Why? 0 25 24 00
0 0  
Q=60,000=4000()
Design heuristics: =155
Q=24 20 19 Outlet =150
0 0 0 Match is not feasible
Violates minimum
 
Above Pinch: Q=6
15 14
Below Pinch: 14 0 13
0 0
 Design Above the Pinch
Stream 2 can match Strea 1 2 3 4
mF  100 400 300 600
only with 4 0 0 0 0
250 240
Stream 1 can match
with either 3 or 4

(a)Put in the matches at

200 190
the pinch
Q=24
(b)Maximize the heat 0
loads to eliminate
streams
150 140 Q=60
(c)See what is left
14 13
0 0
Design above the Pinch
Note the criteria, [FCp]C > [FCp]H is valid
only at the pinch
Not away from the pinch!
Also we know that we are allowed to only
add the heat above the pinch
Also the feasible matches are 2-4 and 1-3
Hence, stream 2 can supply all 240 heat to
stream 4
Stream 1 can supply 60 to stream 3
Thus streams 2 and 3 are exhausted
Also remaining heat of 50 can be given by
stream 1 to 4
Complete Design above the
Pinch
How many HEX?
4 Strea 1 2 3 4
mF  100 400 300 600
Minimum
0 0 0 0
240
heating 250

requirement
Stream T values
are also shown 200 190
H=70
All the T=20
0 T=17
Q=24 8
requirements are 0
T=17
met 0
A feasible design 150 140 Q=60
above the pinch. 14 13
0 0
 Alternative
At the pinch, we have unique match
Away from the pinch, there are more
alternatives
Utility heater
250can be put 250
240 before
250 or after the
HEX 1-4
Q=50
Q=50 182 190
170 178
200 190 200 190
H=70
200 250
200 250
T=17
8 ΔT=18 ΔT=60
ΔT=30 ΔT=72 150 140 150 140

As [a]< As [b] !!
Design Below the Pinch
𝐹  𝐻 𝐶 𝑝𝐻 >¿𝐹 𝐶 𝐶 𝑝𝐶
We need,
Stream 2 can match only with 3
Stream 2 can give away 120 heat to stream
4
What is left?
Stream 1 and 2, both are hot streams
Hence only cold utilities will be required!
Strea 1 2 3
How much? m
Strea 100 400 15 14 600
20+40=60 kBtu/hr m 0 0 0 0
0
How many HEX? 3
Q=2 Q=1 Q=1
0 60 10 90 20
0
Minimum Energy Complete
Design
Minimum
1 2 3 4
cooling 60 300 400
100 200
Minimum 0 0 25 0
24 0
heating 70 0 0
Q=50
Total HEXs 7
H=7
Feasible HEX 20 19 0
0 0
network Q=24
0
15 14 Q=6
14 0 0 0 13
0 C=2 0
Q=12
0 0
C=4 10 90
0 0
Loops in the HENS
From the below eqn we know that, NHEX=5
  Number of = Number of + Number of − 1
( )(
Heatexchangers streams )( )
utilities
Will the minimum energy requirement be
satisfied? No
We saw that with minimum energy
requirement 7 HEXs are required
Thus, 2 extra HEX are present in min
energy case!
Where these 2 HEX come from?
There should be two additional loops
crossing the pinch!
Lets observe the loops in the network that
 Loop- Loop-
1 2
1 2 3 4 1 2 3 4
100 200 300 400 100 200 300 400
0 0 25 0
24 0 0 0 0 0
25 24
0 0 0 0
Q=50 Q=50
H=70
20 19 19
0 0 20 0
Q=24 Q=240
0 0
Q=6 15 14 Q=6
14 20 19 0 0
0 13 14 0 13
0 0 0
C=2 Q=12 0 0C=2 0
0 Q=12
0 0
0
C=4 10 90 C=4 10 90
0 0 0 0

Note the same coolant is used at both the

3
1 2 3 4
100 200 300 400 If we break one
0 0 250 2400 0
loop involving cold
utility, other also
H=70 breaks!
Q=5 We may need to
200 190
0 supply more
Q= energy for such
240 alternative!

150 140 Q=
14 60 13
0 0
Q=
C=2 120
0
C=
40
100 90
Breaking a
Loop
A loop in the HEN corresponds to an extra
HEX
Breaking a loop leads to elimination of a HEX
For any QE, energy requirement is satisfied
How many HEX? 4
1 2 3 4
For QE=20, how many HEX? 3
Stream Stream
1 2  
60+
80 160
 
60+
 
20-  
40+  
120-  
120-

Cold Stream
Utility 3  𝑄 𝐸
180  
40+
60
Three Design Heuristics
 First break the loop that includes the
exchanger with the smallest possible heat
load.
 Always remove the smallest heat load from
a loop.
 If we break a loop that crosses the pinch,
Ifnormally wethe
we violate violate the minimum
minimum energy approach
temperature in
requirements, wethe revised
can restorenetwork.
it using a
concept of path and splitting
Path is a connection between a heater and a
cooler
Path in the
System 1
100
2
200
3
300
4
400
0 0 250 2400 0
H

H=70
Q=5
0 200 190

n
Q=
240

C 150 140 Q=
60
C Q=
C=2 120
0
C=
40
100 90
 Path in a System
We can shift heat along a
path H  
H+
Q
We add QE in the hot
 
Q-
utility
And remove it through
C
cold utility on the same  
C+

path
This is to keep the total
heat load the same in a
stream
This reduces the heat
load from another
 Path in a System
When we add heat to a
H  
H+
heater and shift it along a
Q
path, we must remove the  
Q-
same amount of heat in a
cooler!
This is usually done to C  
C+

restore a minimum
approach temperature
 1.This
 Canprocedure always
heat along the path
2.increases
Transfer the
heatenergy
across the pinch more heat
consumption
in , more heat out
3. Use to restore minimum
 Reducing the No. of
Exchangers
General Rules concerning the design

  procedure
The number of exchangers required for the
overall process is always less than or equal to
that of the minimum energy network.
 If the design procedure for the minimum
energy network is used, there will be normally
be loops across the pinch.
 We can break these loops by transferring heat
across the pinch, but we will introduce at least
one violation of the specified
 We can restore by shifting heat along a path,
which increases the energy consumption of
the process.