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SAJJAD KHUDHUR ABBASCeo , Founder & Head of SHacademyChemical Engineering , Al-Muthanna University, IraqOil & Gas Safety and Health Professional – OSHACADEMYTrainer of Trainers (TOT) - Canadian Center of Human Development
Episode 60 : Pinch Diagram and Heat Integration
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Introduction of Process Integration
Pinch Diagram and Heat Integration
Reference: Notes from course on “Modelling, design and control for process integration”, CAPEC, August 2000 (R.
Dunn)
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Process Integration Tools Allow Analysis of the “Enterprise”
• The optimal allocation of mass and energy within a unit operation, process and/or site.• Optimal allocation can be based on economic, environmental or other important objectives.
Heating Cooling
Mass Integration (Mass Exchange Network – MEN) Energy Integration (Heat Exchange Network – HEN)
Power Pressure
ProductsFeed Stock
By-ProductsSolvents
Chemical Plant
(Enterprise)Effluents
Catalysts
Spent MaterialsMaterial for Utilities(Water, Coal)
Heating Power Cooling
Pressure
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Process Integration Techniques
ReactiveMass Exchange ExchangeNetworks Networks(REAMEN’s)
Mass Exchange Networks (MEN’s)
Process Integration
Process Integration
Heat Exchange Networks (HEN’s)
Combined Heat and Reactive Mass Exchange Networks (CHARMEN’s)
Masswith Regeneration (MEN/REGEN)
Reverse Osmosis Networks (RON’s)
Heat-Induced
Waste Minimization Networks (HIWAMIN’s)
Energy-Induced Separation Networks (EISEN’s)
Pervaporation Network’s (PERVAP’s) Waste
Interception and Allocation Networks(WIN’s)
Heat-Induced Separation Networks (HISEN’s)
Energy-Induced Waste Minimization Networks (EIWAMIN’s)
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4
Heat Exchange Network (HEN)
Want to Identify:– Optimal matching between hot and cold streams to
minimize utility consumption– Minimum number of heat exchangers needed
PlantUnit OperationsRaw Materials
Products&
By-Products
Hot Streams In
Cold Streams In
Cold Streams Out
Hot Streams Out
(Linnhoff, Grossmann et al, 1978-Present)A Heat Exchange Network is a System of One or More
Heat ExchangersHot and Cold Utilities
Heat Exchanger Network
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Therefore, 10x103 BTU/hr must be supplied from utilities (if there are no restrictions on temperature driving force)
How can we check driving force restrictions? Second Law Analysis (You can not transfer heat from a lower temperature to a higher temperature)
5*Ref. Douglas, 1988, Conceptual Design of Chemical Processes, McGraw-Hill Publishers, p. 218.
Consider the problem of two hot stream and two cold streams:
First Law Analysis (Conservation of Energy):
Q F Cp T 4000 BTU (200 100)o F 400x103 BTU / hr hr o F
Q FCp T 1000 BTU (250 120)o F 130x103 BTU / hr hr o F
2 2 2 2
1 1 1 1
Calculate Q3 and Q4
Table 1*
Stream Q available
No. Condition FCp, BTU/(hroF) Tin Tout 103 BTU/hr
1 Hot 1000 250 120 1302 Hot 4000 200 100 4003 Cold 3000 90 150 -1804 Cold 6000 130 190 -360
-10
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Shifted Temperature Scales (using Table 1 data):
100
Hot Temperature Scale Cold Temperature Scale
250
240
200
150
190
140
90
Sources Sinks
These streams need to be cooled
These streams need to be heated
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Temperature Interval Diagram (TID)
Hot Temperature Scale Cold Temperature Scale
250
240
200
140
100
190
130
90
160 150
120 110
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Net Energy Required at Each Interval
Hot Temperature Scale Cold Temperature Scale
Heat Duty Within IntervalsInterval, i250 240FCp 1000 4000 3000 6000 1000 Q
200
140 3 130
100 5
120 4 110
190
90
1 50
2 -40160 150
-80
40
20
Total = -10
Q (FCp) (FCp)
T
Q (1000 4000 3000 6000)(160 140) 80x103
3
Q (1000 4000 6000)(200 160) 40x103
2
Q (1000)(250 200) 50x103
1
cold ,i
i hot ,i
Therefore,
i
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Heat Transfer to and from Utilities for Each Temperature IntervalHot Temperature Scale
250
Cold Temperature Scale
240
50200 190
Hot -40
Cold160
UtilityUtility 150
140 130
120 110
100 20 90
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Cascade Diagram
Hot Temperature Scale Cold Temperature Scale
250 240
200
140
100
190
150
130 Pinch
90
160
50
-40
-80
50Hot
UtilityCold
Utility10700
40 4020 60
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11
Hot Composite CurveTable 2*
Hot streams, oF Cumulative H
Since FCp values are constant, we could have replaced the calculation for H2, H3, H4 with a single expression: H2,3,4=(1000+4000)(200-120)=400,000
Temperature (oF) Plot Becomes the Hot Composite Curve
Enthalpy (1000 BTU/hr)*Ref. Douglas, 1988, Conceptual Design of Chemical Processes, McGraw-Hill Publishers, p. 218.
T=100 H0=0 0
T=120 H1=4000(120-100)=80,000 80,000T=140 H2=(1000+4000)(140-120)=100,000 180,000T=160 H3=(1000+4000)(160-140)=100,000 280,000T=200 H4=(1000+4000)(200-160)=200,000 480,000T=200 H5=1000(250-200)=50,000 530,000
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Hot Composite Curve
270
250
230
210
190
170
150
130
110
900 100 200 300 400
Enthalpy, 1000 BTU/hr
500 600
Tem
pera
ture
(deg
F)
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Cold Composite CurveTable 2.3*
Cold streams, oF Cumulative H
Temperature (oF) Plot Becomes the Cold Composite Curve
Enthalpy (1000 BTU/hr)
*Ref. Douglas, 1988, Conceptual Design of Chemical Processes, McGraw-Hill Publishers, p. 218.
T=90 H0=60,000 60,000
T=130 H1=3000(130-90)=120,000 180,000T=150 H2=(3000+6000)(150-130)=180,000 360,000T=190 H3=6000(190-150)=240,000 600,000
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Cold Composite Curve
210
190
170
150
130
110
900 100 200 300 400
Enthalpy, 1000 BTU/hr500 600 700
Tem
pera
ture
(deg
F)
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Composite Curves
27025023021019017015013011090
Tem
pera
ture
, deg
F
Hot Composite StreamCold Composite Stream at 10 deg F minimum temperature driving force
0 200 400 600
Enthalpy, 1000 BTU/hrComputer Aided process Engineering - Lecture 11 (R. Gani)
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Composite Curves
270
250
230
210
190
170
150
130
110
90
Tem
pera
ture
, deg
F
Hot Composite StreamCold Composite Stream at 10 deg F minimum temperature driving force Cold Composite Stream at 20 deg F minimum temperature driving force
0 200 400 600
Enthalpy, 1000 BTU/hrComputer Aided process Engineering - Lecture 11 (R. Gani)
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Composite “Pinch” Diagram
Temperature Minimum Amount ofCold Utility Required
Minimum Amount of Hot Utility Required
Process to Process Heat Integration
“Pinch” orTminimum
EnthalpyComputer Aided process Engineering - Lecture 11 (R. Gani)
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