Heat integration
Mathematical Techniqes
for the Synthesis of
HENs
(CHAPTER 19, P.345-353)
PROF. KAMIL WAGIALLA
UNIVERSITY OF KHARTOUM-CHEMICAL ENGINEERING DEPARTMENT
COMPUTER-AIDED TARGETING
Qmin Qmin
FOR MINIMUM HEATING
heating AND COOLING
cooling
UTILITIES
(Chapter 19, pages 345 – 349)
Targeting for Minimum Heating and
Cooling Utilities (page 345):
The exchangeable load of the uth hot stream which passes through
the zth interval is:
HH u , z Fu C p ,u Tz 1 Tz
The exchangeable capacity of the vth cold stream which passes
through the zth interval is:
HCv , z f v C p ,v t z 1 t z
Summing up the heating loads and cooling capacities we get:
HH zTotal HH u , z
u passes through int erval z
u 1, 2, ..., N H
HC Total
z HCv , z
v passes through int erval z
v 1, 2, ..., N C
We incorporate next the heating and cooling utilities:
For temperature interval z, the heat load of the uth heating utility is:
HHU u , z FU u C p ,u Tz 1 Tz , where u N H 1, N H 2, ..., N H N H HU
FU u is the flow rate of the uth heating utility.
The sum of all heating loads of the heating utilities in interval z is :
HHU zTotal HHU u , z , where
u passes through int erval z
u N H 1, N H 2, ..., N H N H HU
The total heating load of the uth utulity in the HEN is evaluated by
summing up the individual heat loads over all the intervals:
QH u HHUu , z
z
Similarly, the cooling capacities of the vth cooling utility in the zth interval
is:
For temperature interval z, the heat load of the uth heating utility is:
HCU v , z fU v c p ,v t z 1 t z , where v N C 1, N C 2, ..., N C N C CU
fU v
is the flow rate of the vth cooling utility.
The sum
HCU z HCU v, z , where v N C 1, N C 2, ..., N C N C CU
Total of all cooling capacities of the cooling utilities in interval z is :
v passes through int erval z
The total cooling capacity of the vth utility in the HEN is evaluated by
summing up the individual cooling capacities over all the intervals:
QCv HCU v , z
z
Heat Balance Around Temperature Interval
Residual Heat from Preceding Interval
HH Total HCTotal
z
z
Heat Removed
Heat Added Z HCU Total
z
By Cold Streams
By Hot Streams HHU Total
z
Residual Heat to Subsequent Interval
For the zth temperature interval, we can write the following heat balance
equation:
HHU zTotal HH zTotal rz 1 HCU zTotal HC zTotal rz r 1, 2, ... nint
To ensure a closed energy balance, the residuals entering the first and
leaving the final interval are set to zero, i.e.,
r rn 0
0 int
rz 0, z 1, 2,...,n 0
int
FU u 0 , where u N H 1, N H 2, ..., N H N H HU
fU v 0, where v N C 1, N C 2, ..., N C N C CU
The objective is to minimize the cost of heating and cooling
utilities
CH U
CC v
Let = Cost of uth heating utility, and = Cost of vth cooling
utility
There are 2 cases:
Case One Cost in terms of $/unit flow of utility
CH *FU CC * fU
Objective function:
U U v v
Minimize
Case Two Cost in terms of $/unit heat added or removed by the utility
Objective function:
CH *QH U U CC *QC v v
Minimize
The above function is a LINEAR PROGRAM that can be solved using
software such as LINGO.
Example (Pharmaceutical facility), page 346
330 K 300 K
520 K
320 K
300 K 380 K
550 K
Reactor
Separation
380 K
The cost of the utilities: Washing
Heating 6 ($/ kJ)
Cooling 8 ($/ kJ) purification
Use linear programming to determine the minimum operating
cost.
A value of Δ = 10 K is used.
Stream Data for pharmaceutical facility
Stream Flow RatexSpecific Supply Target
Heat kW/K Temperature, K Temperature, K
10 520 330
5 380 300
? 560 520
19 300 550
2 320 380
? 290 300
Solution
Step 1: Create TID
Step 2: Create TEHL hot streams
Step 3: Create TEHL cold streams
Step 4: Write and execute Linear
program using LINGO software
The Temperature interval Diagram (TID)
Interval Hot Streams Cold Streams
t
T 550
560
1 Hot Utility 520 510
2 380
390
3 380 370
4 320
330
5 300
310
6 290
Refrigerant 300
TEHL for Process Hot Streams
Interval Load of (kW) Load of (kW) Total Load (kW)
1 - - -
2 1300 - 1300
3 100 - 100
4 500 250 750
5 - 100 100
6 - 50 50
TEHL for Process Cold Streams
Interval Capacity of (kW) Capacity of (kW) Total Capacity
(kW)
1 760 - 760
2 2470 - 2470
3 190 20 210
4 950 100 1050
5 380 - 380
6 - - -
The objective function 6=
10( 6 Qmin 810 6 Qmin )3600x8760
heating cooling
min 252.2880 Qmin
= .216 Qheating
189
cooling
Energy balaces for Linear Program :
r1 - Qheating
min = -760
r2 – r1 = -1170
r3 – r2 = -110
r4 – r3 = -300
r5 – r4 = -200
min
– r5 +Qcooling = -50
Lingo program for pharmaceutical example:
min=189.2*Qhmin+252.2*Qcmi r5-r4=100-380;
n; -r5+Qcmin=50;
r1-Qhmin=-760; Qhmin>=0;
r2-r2=1300-2470; Qcmin>=0;
r3-r2=100-210; r1>=0;
r4-r3=750-1050; r2>=0; …r5>=0;
COMPUTER-AIDED
STREAM MATCHING and HEN SYNTHESIS
(Chapter 19, pages 349 – 353)
The synthesis problem can be decomposed into two subnetworks, one
above and one below the pinch ( SNm, where m 1, 2 ).
Definitions:
H m = {u|u H, hot stream u exists SNinm Hm
}, where is the set of
hot streams existingSNmin .
Cm = {v|v S, cold stream v exists SNin }, where
Cm is the set of
m
cold streams existing
SNm in .
H m, z = {u|u
H m , hot stream u exists in interval z
SNm }, where
H m, z
SNm z in
is the set of hot streams existing in interval
Cm, z = {v|v Sm , cold stream v exists in interval
SNzm }, where
Cm, z
is the set of cold streams existing in interval
SNm z in
Heat Balance Around Temperature Interval For hot stream u
r
u, z 1
Q
u,v1,z
Q Heat exchanged
QuH, z u,v2,z
Heat exchanged Z From hot stream
u to cold stream
from Hot Stream Q
v in interval z
u,vSm, z ,z
U in interval z
ru, z
Cont’d:
The upper bound on the exchangeable heat between streams
‘u’ and ‘v’ in SNm, designated by Uu,v,m:
U u ,v ,m min Qu , z , Qv , z
H C
Introduce binary integer : zSN m zSN m
Eu ,v , m 0 when there is no match
Eu ,v , m 1 when there is a match (and hence a heat
exchanger)
Cont’d:
H
Q u,z heat load of hot stream u in interval z
QuH,z Total heat load of hot stream u over all intervals
zSNm
QvC, z heat capacity of cold stream v in interval z
QvC,z is heat capacity of cold stream v in int erval z
QvC,z Total heat capacityof cold stream v over all intervals
zSNm
Steps:
Objective : min E u ,v , m
m 1, 2 uH m vC m
Subject to the following constraints:
Heat balance for each hot stream around each temp interval:
ru , z ru , z 1 u ,v , z u , z
Q
vSN m
Q H
Steps: cont’d
Heat balance for each cold stream around each temp
interval:
u ,v , z v , z
Q
uSN m
Q C
Matching of loads:
Q
zSN m
u ,v , z U u ,v ,m Eu ,v ,m
Steps: cont’d
Non-negativity constraints:
ru , z 0 u , z
Qu ,v , z 0 u , v, z
Binary integer variables for matching streams:
Eu ,v ,m {0,1} u, v, z
Steps: cont’d
The preceding formulation is a mixed-integer linear program
that can be solved using optimization tools (such as LINGO) to
provide information on:
1. The stream matches and
2. exchangeable loads
The solution to the above program may not be unique.
Pharmaceutical facility
First draw TID, cascades, then determine pinch point.
Next construct TEHL for hot and cold streams:
Pharmaceutical facility
interv Total Total of HU Capacity Capacit CU
al of H1 H2 (H3) of C1 y of C2 (C3)
1 - - 2620 760 - -
2 1300 - - 2470 - -
3 100 - - 190 20 -
4 500 250 - 950 100 -
5 - 100 - 380 - -
PINCH
6 - 50 - - - 50
Cont’d:
Next, exchangeable loads above and below pinch:
Above Pinch Below Pinch
Stream Load (kW) Stream Load (kW)
H1 1900 H1 0
H2 350 H2 50
HU 2620 HU 0
C1 4750 C1 0
C2 120 C2 0
CU 0 CU 50
Cont’d:
Next, determine possible matches above and below
pinch:
Above pinch : E111, E121, E211, E221, E311, E321.
Below pinch: E232 only.
The above combinations may be taken from TID diagram as
shown in next slide:
The Temperature interval Diagram (TID)
Interval Hot Streams Cold Streams
t
T 550
560
1 Hot Utility 520 510
2 380
390
3 380 370
4 320
330
5 300
310
6 290
Refrigerant 300
LINGO:
min=E111+E121+E211+E221+E311+E321+E232; !HEAT BALANCE FOR H3;
!HEAT BALANCE FOR H1; r31+Q311=2620;
r12+Q112=1300; r32-r31+Q312=0;
r13-r12+Q113+Q123=100; r33-r32+Q313+Q323=0;
r14-r13+Q114+Q124=500; r34-r33+Q314+Q324=0;
r15-r14+Q115=0; r35-r34+Q315=0;
-r15+Q116+Q136=0; -r35=0;
!HEAT BALANCE FOR H2;
r24+Q214+Q224=250;
r25-r24+Q215=100;
-r25+Q216+Q236=50;
LINGO: cont’d
!HEAT BALANCE FOR C1; !HEAT BALANCE FOR C3;
Q311=760; Q236=50;
Q112+Q312=2470; !MATCHING OF LOADS;
Q113+Q313=190; Q112+Q113+Q114+Q115<=1900*E111;
Q114+Q214+Q314=950; Q214+Q215<=350*E211;
Q115+Q215+Q315=380; Q123+Q124<=120*E121;
!HEAT BALANCE FOR C2; Q224<=120*E221;
Q123+Q323=20; Q311+Q312+Q313+Q314+Q315<=2620*E311;
Q124+Q224+Q324=100; Q323+Q324<=120*E321;
Q236<=50*E232;
LINGO: cont’d
!MATCHING OF LOADS;
! Matches Above the pinch:;
Q112+Q113+Q114+Q115<=1900*E111; ! 1900 < 4750;
Q214+Q215<=350*E211; ! 350 < 4750;
Q123+Q124<=120*E121; ! 120 < 1900;
Q224<=120*E221; ! 120 < 350;
Q311+Q312+Q313+Q314+Q315<=2620*E311; ! 2620 < 4750;
Q323+Q324<=120*E321; ! 120 < 2620;
! Matches Below the pinch:;
Q236<=50*E232; ! 50 for both H2 and C3;
LINGO: cont’d
!BINARY INTEGERS; !NONNEGATIVITY CONSTRAINTS;
@BIN(E111); r12>=0;r13>=0;r14>=0;r15>=0;....
@BIN(E211); Q112>=0;Q113>=0;Q123>=0;Q114>=0;
@BIN(E121); Q124>=0;Q115>=0;Q116>=0;Q136>=0;...
@BIN(E221);
@BIN(E311);
@BIN(E321);
@BIN(E232);
Global optimal solution found.
Objective value: 5.000000
Objective bound: 5.000000
Infeasibilities: 0.2273737E-12
Extended solver steps: 1
Total solver iterations: 15
Variable Value Reduced
Cost
E111 1.000000
1.000000
E121 1.000000
1.000000
E211 1.000000
1.000000
E221 0.000000
1.000000
E311 1.000000
1.000000
E321 0.000000