Energy Conservation in Process Industries

by:
Dr.James Varghese
jamesvar@gmail.com
Mechanical Engineering,
School of Engineering
Cochin University of Science and
Technology

Outline
Process
Process energy requirement
PTA
Heat exchanger network synthesis
Network approach temperature optimization

Chemical process plant

A chemical plant is an industrial process plant
that manufactures (or otherwise processes)
chemicals, usually on a large scale. The general
objective of a chemical plant is to create new
material wealth via the chemical or biological
transformation and or separation of materials.
In a plant, each of the unit operations commonly
occur in individual vessels or sections of the
plant called units.
http://en.wikipedia.org/wiki/Chemical_process

Chemical process design

Energy, how much ?
Raw materials

Products
Processes
Processes
Reactions,
Reactions,separations,
separations,Mixing,
Mixing,
pressure
pressurechange
change,heating,
,heating, cooling,
cooling,etc
etc

Cold stream:
Need to be heated (supply heat)
Hot stream:
Need to be cooled (remove heat)

Chemical reaction energy

requirements
Q

45
P1

175
R1
20

155
112

65

125

Reactor2
Q

15

Q
R2

Energy targeting
Q
1300
2400

45

175

10
Q

125

65

3700
155

20

112

40

2700

1080
3780

Mcp

40

20

15

What is the minimum heat to be supplied (hot utility), heat to be

removed (cold utility) ?
Heat exchanger network design ?

Temperature (K)

Hot composite curve (HCC)

175

H1(10)

125

H1(10)
H1+H2(10+40)

H2(40)
65

45

H1(10)
0

1000

Heat (kW)

2000

1000

2000

Heat (kW)

Add MCp of streams in the same temperature range

3000

Temperature (K)

Hot composite curve (HCC)

175

H1(10)

125

H1(10)
H1+H2(10+40)

H2(40)
65

H1(10)

45
0

1000

Heat (kW)

2000

1000

2000

Heat (kW)

3000

Cold composite curves

175

C4(15)
C3(20)

C4(15)

65

45
0

2000

Heat (kW)

4000

Temperature (K)

Temperature (K)

125

C3+C4(20+15)
C3(20)
0

2000

Heat (kW)

4000

Grand composite curve (GCC)

550

Temperature (K)

Hot utility required

450
30K

HCC

350

CCC

Pinch

70K

cold utility required

250
0

1000

2000

3000
4000
Heat (kW)

5000

Minimum approach Tmin increases

6000

Heat load increases

Algorithm Problem table algorithm (PTA)

Targeting
Process to process heat recovery

Hot utility required

Temperature (K)

175
125

HCC
CCC
65
Pinch 30K

45

cold utility required

0

heat (kW)
The composites can be moved laterally

Minimum approach temperature

increased
Hot utility required
Temperature (K)

175
125

HCC
CCC
65
Pinch 70K

45

cold utility required

0

heat (kW)

The hot utility and cold utility increased

Process to process heat recovery reduced
Heat exchanger cost reduced
Trade off between energy and capital to optimize the minimum
approach temperature

Energy targeting
175

125

45

Mcp
10

65

155

20

112

40

40

20

15

Problem Table Algorithm

Assume T, Ex: 20 C
Step 1: T/2 is subtracted from
hot stream and T/2 is added to
cold stream temperature
Step 2: These shifted
temperatures are sorted in
descending order

Hot stream

175
125

45
65

Cold stream

20
40

155
112

Interval

Tint C

0
1
2
3
4
5
6

175-10,155+10 =165
112+10=122
125-10=115
65-10=55
40+10=50
45-10=35
20+10=30

Problem Table Algorithm

Interval

Tint C

0
1
2
3
4
5
6

Mcp,int

165
122
115
55
50
35
30

0
10
25
-15
25
10
20

Qint,KW
0
430
175
-900
125
150
100

Hot stream

165
115

35
55

10
40

Cold stream

30
50

165
122

20
15

Step4: Calculate net Mcp

in each interval
Mcp,int= Mcp,c- Mcp,h
Step 5: Calculate
enthalpy in each interval
Qint= Mcp,int x Temp.diff
for that interval

Problem Table Algorithm

Interval

Tint C

0
1
2
3
4
5
6

165
122
115
55
50
35
30

Mcp,int
0
10
25
-15
25
10
20

Qint,KW
0
430
175
-900
125
150
100

Q,cas,
kW

R,cas,
kW

0
-430
-605
295
170
20
-80

605
175
0
900
775
625
525

Step6: Calculate cascaded heat, subtract net enthalpy

from the previous interval, Qcas
Step 7: Most negative Qcas in each interval is
subtracted from each value in that column
R,cas = Q, cas min(Qcas)

Grand composite curve (GCC)

Useful to fix the utility levels

Problem Table Algorithm (PTA) method (Linnhoff and Flower, 1978)

Heat exchanger network meeting the

energy target
Important Pinch Design Criteria
Number Criterion
No utility cooling above the pinch
Every hot stream must be brought to its pinch temperature by cold stream
Nh Nc above the pinch
Nh Nc below the pinch
If the above condition is not satisfied then stream splitting is necessary

MCp Criterion
MCp, h MCp, c above the pinch
MCp, h MCp, c below the pinch
If the above condition is not satisfied then stream splitting is necessary

Energy targeting
175

125

45

Mcp
10

125

65

155

20

112

40
105
Divides the problem into two Above the
pinch and Below the pinch

40

20

15

Energy targeting above pinch

7.9

175

45

Mcp
10

2.1
155

125

125

124.75

65

20

H
605

40

20

105

395

40

112
105

105

Satisfies number criterion not MCp

criterion so split the streams

15

Energy targeting
175

Mcp

125

97.5

45

10

525
Mc-23.75

125

65

40

Mc-16.25
155

Mc-16.77

20

105

1425
275

112

Satisfies number criterion MCp criterion

not satisfied so split the streams

20

Mc-3.23
15

105

975

40

Network for 20C minimum T

175

125

7.9

97.5

Mcp
45

525

125

Mc-23.75

2.1

65

10

3700

40

Mc-16.25
124.75

155

Mc-16.77

H
3780

605

20

105

395

1425
275

112

20

Mc-3.23
15

105

105

975

40

Heat exchanger network synthesized based on

pinch principles meeting the target set.
Further simplifications possible using the network
evolution principles.

Total Annualised Cost

Cost of heat exchanger
Operating cost

Capital recovery factor

TAC = CRF x Chx + Copr

i( 1+ i)n
CRF =
( 1+ i)n 1

Optimum temperature difference

Cost $/Year

Energy

TAC

Capital
Tmin

References
The pinch design method for heat exchanger networks, Linnhoff, B.
and E. Hindmarsh, Chem. Eng. Sci., 38(5), 745763 (1983)
Understanding heat exchanger networks, Linnhoff, B., E. Mason, and I.
Wardle, Comp.Chem. Eng., 3, 295302 (1979).
Heat Exchanger Network Synthesis: Process Optimization by Energy
and Resource Analysis, Uday V. Shenoy, Gulf Professional Publishing,
1995
J. Varghese and S. Bandyopadhyay, Fired Heater Integration into Total
Site and Multiple Fired Heater Targeting, Applied Thermal Engineering,
42, 111-118, 2012.
J. Varghese and S. Bandyopadhyay, Improved areaenergy targeting for
fired heater integrated heat exchanger networks, Chemical
Engineering Research and Design, 90, 213219, 2012.
Korobeinikov, A. and McCarthy, J. and Melnik, A. and Mooney, E. and
Rojas, J. and Semkov, K. and Varghese, J. and Zhelev, T, Model based
methodology development for energy recovery in ash heat exchange
systems Mathematics in Industry,
http://www.maths-in-industry.org/miis/567/ , 2012.

References contd.
S. Bandyopadhyay ,J. Varghese and V Bansal, Targeting for cogeneration potential
through total site integration, Applied Thermal Engineering, 30 , 614, 2010.
J. Varghese and S. Bandyopadhyay, Energy integration of fired heaters into overall
processes,International Journal of Environment and Sustainable Development (IJESD)
Vol. 8, No. 1, 36-59, 2009.
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Conference on Process Integration, Modeling and Optimisation for Energy Saving and
Pollution Reduction (PRES 2008) in conjunction with 18th International Congress of
Chemical and Process Engineering (CHISA), Praha, Czech Republic, August 24-28,
2008.
J. Varghese and S. Bandyopadhyay, Integration of multiple fired heaters into the process
and network synthesis, Ind. Eng. Chem. Res. 46, 5631-5644, 2007.
J. Varghese and S. Bandyopadhyay, Integration of fired heaters into total site, 19th
International Conference on Efficiency, Cost, Optimization, Simulation and
Environmental Impact of Energy Systems (ECOS 2006),Crete, Greece,Vol 2,715-722,
12-14 July, 2006.
J. Varghese and S. Bandyopadhyay, Targeting for energy integration of multiple fired
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