Process Engineering

Process Synthesis
PROCESS ENGINEERING
HENS Heat Exchange

Network Synthesis
ALVARO ORJUELA
Process Synthesis
Column Configuration
Heat Available?
1
A
B
C
B,C
Heat Exchanger network Synthesis - HENS

The problem is defined as follows: Given
A set of hot process streams to be cooled and a set of cold
process streams to be heated
The flow rates and the inlet and outlet temperatures for all
the process streams
The heat capacity for each stream versus their temperatures
as they pass through the heat exchange process
The available utilities, their temperatures, and their costs per
unit of heat provided or removed
Determine the heat exchange network for energy recovery
that will minimize the annual cost of the equipment plus the
annual cost of utilities
Heat Exchanger network Synthesis - HENS

We have to know the pressure of the stream as it passes the
through the exchange network because phase changing
(latent heat) can be present
ADVANTAGES
We can predict the less amount of utilities required in the
process
We can estimate the fewest number of heat exchangers that
we will require
We can estimate the cost of the network
ALL THESE WITHOUT INVENTING OR DESIGNING THE
NETWORK
Problem description
Alternative I Tmin = 20 F
A reactor is fed with two reactants available at 100 F.

Reaction occurs at 580 F and it is slightly exothermic, so
products leave the reactor at 600 F. For separation
purposes reactor outlet must be cooled down to 200 F.
FCP = 1
FCP = 2
580 F
1
100 F
100 F
Stream Condition
1
2
3
Cold
Cold
Hot
600 F
580 F
FCP,
Tin (F)
BTU/h F
1
100
2
100
3
600
NET HEAT
Tout (F)
580
580
200
226.6 F
FCP = 1
280 F
FCP = 1
BTU
h
q1 = Q1 = FC P T = 3 ( 600 T ) = 960
T = 280 F
FCP = 3
q1 = FC P t = 2 (100 580 ) = 960
Q available
BTU/h
-480
-960
1200
-240
BTU
h
q2 = Q2 = FC P T = 3 ( 280 T ) = 160
T = 226.66 F
q2 = FC P t = 1 (100 260 ) = 160
440 F
100 F
FCP = 2
Alternative II Tmin = 20 F
FCP = 3
580 F
600 F
580 F
FCP = 1
FCP = 1
100 F
100 F
420 F
200 F
FCP = 2
FCP = 3
580 F
FCP = 2
226.6 F
FCP = 3
600 F
FCP = 2
200 F
1
200 F
580 F
580 F
100 F
Alternative II Tmin = 20 F
100 F
260 F
100 F
1580 F
600 F
200 F
200 F
200 F
BTU
h
q1 = Q1 = FCP T = 1 ( 600 T ) = 400
T = 200 F
q1 = FC P t = 1 (100 580 ) = 480
BTU
h
q1 = Q1 = FCP T = 3 ( 600 T ) = 480

T = 440 F
q1 = FC P t = 1 (180 580 ) = 400
BTU
h
q2 = Q2 = FC P T = 3 ( 440 T ) = 640
T = 226.66 F
q2 = FC P t = 2 (180 580 ) = 800
BTU
h
q2 = Q2 = FC P T = 2 ( 600 T ) = 800
T = 200 F
q2 = FC P t = 2 (100 420 ) = 640
Definition of the problem
Definition of the problem
First law of thermodynamics calculation does not take into

account driving force, so secondsecond-law analysis is required
FCP,
Stream Condition
Tin (F)
BTU/h F
1
Hot
1000
250
2
Hot
4000
200
3
Cold
3000
90
4
Cold
6000
130
NET HEAT
Tout (F)
Q available
BTU/h
120
100
150
190
Heat available (first stream) Q1 = F1CP1T1 = F1CP1 (TIN TOUT )

BTU
Q1 = 1000

h F

( 250 120 ) F
Q1 = 130 103 BTU / h
Stream Condition
1
2
3
4
Hot
Hot
Cold
Cold
FCP,
Tin (F)
BTU/h F
1000
250
4000
200
3000
90
6000
130
NET HEAT
Tout (F)
120
100
150
190
Q available
BTU/h
130000
400000
-180000
-360000
-10000
Temperature Interval
Temperature Interval
Establish a minimum driving force between hot and cold

streams (for example 10 F)
Put side by side two scales of temperatures, hot and cold
scale. Cold scale is shifted by the minimum driving force
Draw temperature intervals and streams using arrows. Head
is outlet temperature, tail is inlet temperature.
H1
250 F
240 F
200 F
190 F
150 F
140 F
100 F
90 F
Define temperature intervals using inlet and outlet

temperatures of all streams
In each interval we can transfer heat form hot streams to
cold streams because the minimum temperature driving
force is adequate (
(Tmin = 10 F)
250 F
H1
H2
200 F
H2
160 F
140 F
C2
250 F
240 F
200 F
190 F
150 F
140 F
100 F
90 F
C2
120 F
C1
100 F
Heat Cascade
Net Energy at Every Interval
Evaluate heat transfer in each interval
Summation of all available heat at each interval is identical

to the result obtained by first law calculation
Qi = ( FCP ) HOT ( FCP )COLD Ti
For the third interval
250 F
Q4 = (1000 + 4000 ) ( 3000 + 6000 ) (160 140 )

BTU
Q4 = 80000
h
250 F
H1
H1
250 F
240 F
200 F
190 F
50000
FCP=4000
H2
200 F
FCP=6000
2
200 F
H2
200 F
3
4
160 F
150 F
140 F
C2
140 F
160 F
140 F
100 F
100 F
90 F
150 F
140 F
100 F
90 F
Heat Transfer Alternative Cascade Diagram

Q (BTU/h)
240 F
250 F
190 F
200 F
240 F
90 F
- 10000
Poor engineering!!! Transferring energy from the highest

temperatures directly to a cold utility rather than using this
available heat in lowerlower-temperature intervals where is
required
150 F
100 F
HOT UTILITY
HOT UTILITY
140 F
40000
- 40000
70000
10000
- 80000
40000
20000
40000
COLD UTILITY
20000
50000
COLD UTILITY
100 F
- 80000
40000
20000
- 10000
50000
150 F
C1
C1
Q (BTU/h)
250 F
- 40000
- 80000
40000
Heat Transfer Using Utilities
200 F
C2
120 F
100 F
120 F
- 40000
FCP=3000
190 F
Q (BTU/h)
FCP=1000
250 F
240 F
C1
190 F
140 F
2000
90 F
- 10000
Energy integration!!! Only one hot utility and one cold utility
are required for the process
Low cost utilities (low temperature)
Information from Cascade Diagram
TemperatureTemperature-Enthalpy Diagram
Minimum utility loads From cascade diagram we can

compute the minimum heating requirement (70000 BTU/h)
and the minimum cooling requirement (60000 BTU/h). The
difference still matches first law, but now minimum utilities
requirement fulfills second law.
Pinch Temperature There is no energy transfer between
third and fourth temperature intervals. This is the pinch
temperature (140 F for hot stream or 130 F for cold
streams, 135 F average ). Above we only supply heat,
below we only reject heat to a cold utility
What about the minimum temperature approach or minimum
driving force (
(Tmin=10 F)? We shift temperature scales,
heat loads in each interval and minimum utilities
requirements. Visualize in T vs. H diagram
Calculate minimum heating and cooling loads using the

cascade (heating requirement =70000 BTU/h, cooling
requirement = 60000 BTU/h)
Define enthalpy of the coldest temperature of any hot stream
as our base condition. (at T = 100 F H = 0 BTU/hr)
Calculate the cumulative heat available in the sum of all the
hot streams as we move to higher temperature intervals
Hohmann/Lockhart
Hohmann/Lockhart Composite Curve
T (F)
90
110
130
150
190
h (BTU/h)
h0 = 60000
h1 = 3000 (110-90) = 60000
h2 = 3000 (130-110) = 60000
h3 = (3000+6000) (150-130) = 180000
h4 = 6000 (190-150) = 240000
Cumulative H (BTU/h)
60000
120000
180000
360000
600000
H (BTU/h)
100
H0 = 0
120
H1 = 4000 (120-100) = 80000
80000
140
H2 = (1000+4000) (140-120) = 100000
180000
160
H3 = (1000+4000) (160-140) = 100000
280000
200
H4 = (1000+4000) (200-160) = 200000
480000
250
H5 = 1000 (250-200) = 50000
530000
T (F)
At the lowest temperature of any cold stream (at T = 90 F)

we choose the enthalpy as the minimum cooling
requirement (cooling requirement = 60000 BTU/h)
at T = 90 F h = 60000 BTU/hr
Calculate the cumulative enthalpy as the sum of all the cold
streams as we move to higher temperature intervals
T (F)
250
240
230
220
210
200
190
180
170
160
150
140
130
120
110
100
90
HOT
COLD
Cold
utility
required
70000
T (F)
1
2
3
4
110000
Hot
utility
required
120000
200
300
400
300
400
500
500
Enthalpy (BTU/h)
600
700
Millares
Hot
Hot
Cold
Cold
FCP,
kW/ C
8.79
10.55
7.62
6.08
600
Millares
Calculate composite curve using Tmin = 10 C

Stream Condition
Cold
utility
required
100
200
Some Practice
HOT
COLD DT=10
COLD DT=20
100
Enthalpy (BTU/h)
What if we choose the enthalpy of the cold stream at T = 90

F = 110000 BTU/h (a different cooling requirement)
250
240
230
220
210
200
190
180
170
160
150
140
130
120
110
100
90
Hot
utility
required
60000
Plot T vs H COMPOSITE CURVE
Cumulative H (BTU/h)
Tin (C)
Tout (C)
160
249
60
116
93
138
160
260

Process Engineering

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Process Engineering

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Process Synthesis

HENS Heat Exchange

Heat Exchanger network Synthesis - HENS

Heat Exchanger network Synthesis - HENS

A reactor is fed with two reactants available at 100 F.

q1 = FC P t = 2 (100 580 ) = 960

q2 = FC P t = 1 (100 260 ) = 160

q1 = FC P t = 1 (100 580 ) = 480

q1 = FC P t = 1 (180 580 ) = 400

q2 = FC P t = 2 (180 580 ) = 800

q2 = FC P t = 2 (100 420 ) = 640

Definition of the problem

Definition of the problem

First law of thermodynamics calculation does not take into

Heat available (first stream) Q1 = F1CP1T1 = F1CP1 (TIN TOUT )

Q1 = 130 103 BTU / h

Establish a minimum driving force between hot and cold

Define temperature intervals using inlet and outlet

Net Energy at Every Interval

Evaluate heat transfer in each interval

Summation of all available heat at each interval is identical

Qi = ( FCP ) HOT ( FCP )COLD Ti

For the third interval

Q4 = (1000 + 4000 ) ( 3000 + 6000 ) (160 140 )

Heat Transfer Alternative Cascade Diagram

Poor engineering!!! Transferring energy from the highest

Heat Transfer Using Utilities

Information from Cascade Diagram

Minimum utility loads From cascade diagram we can

Calculate minimum heating and cooling loads using the

H1 = 4000 (120-100) = 80000

H2 = (1000+4000) (140-120) = 100000

H3 = (1000+4000) (160-140) = 100000

H4 = (1000+4000) (200-160) = 200000

H5 = 1000 (250-200) = 50000

At the lowest temperature of any cold stream (at T = 90 F)

Calculate composite curve using Tmin = 10 C

What if we choose the enthalpy of the cold stream at T = 90

Plot T vs H COMPOSITE CURVE

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