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1
The heat and
material
2
3
4
Main points from onion
balance is at
this boundary
Reactor
Separator
diagram
Heat exchange
network
Design of a process starts with the reactors.
Utilities Separator can be designed for known feeds,
products, recycle concentrations and flow rates.
Site-Wide Utilities
Fig. 2 Onion Diagram For heat and material balance, heat exchange
network (HEN) can be designed.
For remaining heating and cooling duties, the
utility system is designed.
PROBLEM ADDRESSED
Generally two types of problem are
addressed:
• Creating New Designs
This is related to the design of HEN for a new
plant, which is in design stage.
100
Below Above
50 pinch pinch HCC
QCmin CCC
0
0 1000 2000 3000 4000 5000
Heat Content Q (kW)
Fig. 6. The HCC and CCC show the heat availability and heat
requirement for the overall process
Analytical Procedure
Problem Table Algorithm (PTA)
For the calculation of energy targets, only the inlet temperatures,
outlet temperature and heat capacity flow rates are required.
The steps involved in PTA are:
• Determination of temperature intervals
• Calculation of net MCP in each interval
MCp,int = Σ MCp,c – Σ MCp.h for each interval
• Calculation of net enthalpy in each interval
• Calculation of cascaded heat
• Revision of cascaded heat
• Determination of energy targets
Implementation of Problem Table Algorithm
0 165 0 0 0 605
1 122 10 430 -430 175
2 115 25 175 -605 0
3 55 -15 -900 295 900
4 50 25 125 170 775
5 35 10 150 20 625
6 30 20 100 -80 525
stream
H1 H2 C3 C4
MCp
10 40 20 15
Concept of Pinch
140
HU2 High temperature
120 process sink profile
Pinch
100
Low temperature
T (*C )
40
20
CU1
0
0 100 200 300 400 500 600 700 800 900 1000
Heat flow Q (kW)
200
180
160
140 Th,i.
120 BHCC
T (C)
100
80 Interval i. Tc,i.
Th,i.-1
60 BCCC
40
Tc,i.-1
20
0
0 1000 2000 3000 4000 5000
Heat Content Q (kW)
Fig.8. The balenced composite curves
Fig. 4: Potential energy savings
in some major industrial sectors
Steam
Steam
Recycle
Recycle
Steam
Separator
Separator
Product
Feed Product
Feed
Cooling mater
Figure.6 Figure.7
RETROFIT PROJECT
The pinch technology principle is applied on various
projects. One such project, Fig. 8, consists of a complex
refining system. The process is already highly integrated,
with various streams being heat-exchanged to reduce overall
energy requirements.
Application of pinch technology in this project results a
minimum energy target of about 31 MW for the hot utility,
which is steam. The original process consumed nearly
39 MW of steam. Thus, the “scope” for improvement is 8 MW
or 20% of original demand.
A brief analysis of the existing flow sheet uncovered the
specific reasons for current utility requirements being
greater than the target:
1. One instance of utility heating below the pinch.
2. One instance of utility cooling above the pinch.
These violations totaled 8MW. If eliminated, they would bring
the utility requirements to target. The problem was, it would
take six new exchangers and a substantial new investment
to accomplish this.
17,000 lb/hr Steam
Feed and
recycle Recycle
Recycle
20
psi
Steam 70
psi
1 2 3 4 5
Reactor
Flash
Stripper
Preheater
New exchangers
15
psi
Steam 60
psi
1 2 3 4 5
Reactor
Flash
Preheater Stripper
Recycle