Composite Curves

ENGM071 - Process and Energy Integration

Outline
• Enthalpy balance
• Composite curves
• Trade-off Between Heat Recovery and Δ𝑇𝑚𝑖𝑛

2
Revisiting Problem 2 (WS1)
COND
60° CP = 20
180°
C
80°
C1 R2
120°

H CP = 80 R1
REB
130° 100°
120°
C CP = 40 H CP = 36

40° 30°

3
Revisiting Problem 2 (WS1)
Straightforward solution Optimal solution

4
Revisiting Problem 2 (WS1)
Steam CW Units
COND 1200 360 4
60°
180°
80°
2000
C1 R2
120°

Are 1200 units of steam

H 1200 R1
REB really necessary?
130° 100°
120°

3240
C 360 30°
40°
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Enthalpy Balance

6
Enthalpy Balance (continued)
Balance 1 Balance 2

How to find minimum 𝑄𝐻 and 𝑄𝐶 ?

Take temperature into account: Δ𝑇𝑚𝑖𝑛 !
7
 Composite curves:
dealing with several streams

8
A four-stream problem

A simple flowsheet with two hot streams and two cold streams
9
Stream Data Extraction

Supply temp. Target temp.

Stream Type Δ𝐻, kW CP, kW/°C
𝑇𝑆 , °C 𝑇𝑇 , °C

Reactor 1 Feed Cold 20 180 3200 20

Reactor 1 Product Hot 250 40 -3150 15

Reactor 2 Feed Cold 140 230 2700 30

Reactor 2 Product Hot 200 80 -3000 25

Δ𝐻 = 𝐶𝑃 ∙ Δ𝑇

10
Hot streams
280

240

200
Temperature (°C)

160 ∑Δ𝐻 = 6150 kW

120

80

40
3150 kW 3000 kW
0
0 1000 2000 3000 4000 5000 6000 7000
Heat Flow (kW)

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Heat integration
Important considerations:
• How much heat is available (or required)
• How hot that heat is (or needs to be)

Streams’ temperature changes

How much heat is there over a temperature range?

This heat can come from different streams!

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Hot streams
Heat available in temperature intervals
280

240
200-250°C Δ𝐻 = 15 × 250 − 200
= 750 kW
200
Temperature (°C)

160 Δ𝐻 = 15 × 200 − 80
80-200°C +25 × 200 − 80
120 = 4800 kW

80
40-80°C Δ𝐻 = 𝐶𝑃 Δ𝑇
40 = 15 × 80 − 40
= 600 kW
0
0 1000 2000 3000 4000 5000 6000 7000 ∑Δ𝐻 = 600 + 4800 + 750
Heat Flow (kW) = 6150 kW

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 Hot streams
… in tabular form
Temp. Δ𝐻 =
Interval ∑𝐶𝑃, Cumulative
interval, Δ𝑇
𝑇, °C kW/°C Δ𝐻
Δ𝑇 ⋅ ∑𝐶𝑃
250 6150
50 15 750 Δ𝐻 = 15 × 250 − 200 = 750 kW
200 5400
120 40 4800 Δ𝐻 = (15 + 25) × 200 − 80 = 4800 kW
80 600
40 15 600 Δ𝐻 = 15 × 80 − 40 = 600 kW
40 0

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 Hot streams
The hot composite curve is now easy to construct!
280
Temp. Δ𝐻 =
Interval ∑𝐶𝑃, Cumulative
interval, Δ𝑇 240
𝑇, °C kW/°C Δ𝐻
Δ𝑇 ⋅ ∑𝐶𝑃
250 6150 200

Temperature (°C)
50 15 750
160
200 5400
120 40 4800
120
80 600
40 15 600
80
40 0
40

0
0 1000 2000 3000 4000 5000 6000 7000
Heat Flow (kW)

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Cold streams
Cold stream data

Supply temp. Target temp.

Stream Type Δ𝐻/kW CP / (kW/°C)
𝑇𝑆 /°C 𝑇𝑇 /°C

Reactor 1 Feed Cold 20 180 3200 20

Reactor 2 Feed Cold 140 230 2700 30

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Cold streams
280

240 ∑Δ𝐻 = 5900 kW

200
Temperature (°C)

160

120

80

40
3200 kW 2700 kW
0
0 1000 2000 3000 4000 5000 6000 7000
Heat Flow (kW)

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Cold streams
Heat available in temperature intervals
280

240

200 180-230°C Δ𝐻 = 30 × 50 = 1500 kW

Temperature (°C)

160 140-180°C Δ𝐻 = 20 + 30 × 40 = 2000 kW

120

80 20-140°C Δ𝐻 = 20 × 120 = 2400 kW

40

0
0 1000 2000 3000 4000 5000 6000 7000 ∑Δ𝐻 = 2400 + 2000 + 1500
Heat Flow (kW) = 5900 kW

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 Cold streams
… in tabular form
Temp. Δ𝐻 =
Interval ∑𝐶𝑃, Cumulative
interval, Δ𝑇
𝑇, °C kW/°C Δ𝐻
Δ𝑇 ⋅ ∑𝐶𝑃
230 5900
50 30 1500 Δ𝐻 = 30 × 230 − 180 = 1500 kW
180 4400
40 50 2000 Δ𝐻 = (20 + 30) × 180 − 140 = 2000 kW
140 2400
120 20 2400 Δ𝐻 = 20 × 140 − 20 = 2400 kW
20 0

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 Cold streams
The cold composite curve is now easy to construct!
280
Temp. Δ𝐻 =
Interval ∑𝐶𝑃, Cumulative
interval, Δ𝑇 240
𝑇, °C kW/°C Δ𝐻
Δ𝑇 ⋅ ∑𝐶𝑃
230 5900 200

Temperature (°C)
50 30 1500
160
180 4400
40 50 2000
120
140 2400
120 20 2400
80
20 0
40

0
0 1000 2000 3000 4000 5000 6000 7000
Heat Flow (kW)

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Hot and Cold Composite Curves
Putting them together
280

240
The ‘kink’ that will
200 define the pinch
Temperature (°C)

160

120

80

40

0
0 1000 2000 3000 4000 5000 6000 7000 8000
Heat Flow (kW)

Job done? Are we recovering heat?

What about Δ𝑇𝑚𝑖𝑛 ? 21
Hot and Cold Composite Curves
Let’s assume a value Δ𝑇𝑚𝑖𝑛 = 20°C
280

240

200 Pinch
Temperature (°C)

160

120 Δ𝑇𝑚𝑖𝑛 = 20°C

80

40

0
0 1000 2000 3000 4000 5000 6000 7000 8000
Heat Flow (kW)
𝑄𝐶𝑚𝑖𝑛 = 1400 kW 𝑄𝐻𝑚𝑖𝑛 = 1150 kW

Energy targets
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 Trade-off Between
Heat Recovery and Δ𝑇𝑚𝑖𝑛

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Reducing minimum approach T
Δ𝑇𝑚𝑖𝑛 = 10°C
280

240

200
Pinch
Temperature (°C)

160

120 Δ𝑇𝑚𝑖𝑛 = 10°C

80

40

0
0 1000 2000 3000 4000 5000 6000 7000 8000
Heat Flow (kW)
𝑄𝐶𝑚𝑖𝑛 = 1000 kW 𝑄𝐻𝑚𝑖𝑛 = 750 kW

Energy targets
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Optimising Δ𝑇𝑚𝑖𝑛
Economic trade-offs

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Minimum approach temperature
Typical DTmin values:
Industrial Sector Experience DTmin Values Comments

Oil Refining 20-40ºC Relatively low heat transfer

coefficients, parallel composite
curves in many applications,
fouling of heat exchangers

Petrochemical 10-20ºC Reboiling and condensing duties

provide better heat transfer
coefficients, low fouling

Chemical 10-20ºC As for Petrochemicals

Low Temperature 3-5ºC Power requirement for

Processes refrigeration system is very
expensive. DTmin decreases with
low refrigeration temperatures

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Summary
• All hot and all cold streams can be represented
collectively by Composite Curves

• Composite Curves are used to target heat recovery

• Energy targets depend on the value of Δ𝑇𝑚𝑖𝑛

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