140 CHAPTER 3 FUNDAMENTALS OF ENERGY BALANCES AND ENERGY UTILIZATION

(Linnhoff March Ltd.), and UniSim ExchangerNetTM (Honeywell Inc.) allow the
design engineer to plot composite curves, optimize DTmin , set targets for multiple
utilities, and design the heat exchanger network.
Most of these programs are able to automatically extract stream data from process
simulation programs, although great care should be taken to check the extracted data.
There are many possible pitfalls in data extraction; for example, not recognizing
changes in the CP of a stream or partial vaporization or condensation of a stream, any
of which could lead to a kink in the stream T-H profile. See Smith (2005) for more
information on data extraction.
The commercial pinch technology tools also usually include automatic heat
exchanger network synthesis features. The automatic synthesis methods are based
on MINLP optimization of superstructures of possible exchanger options (see Chap-
ter 1 for discussion of MINLP methods). These tools can be used to arrive at a
candidate network, but the optimization must be properly constrained so that it
does not introduce a large number of stream splits and add a lot of small exchangers.
Experienced designers seldom use automatic heat exchanger network synthesis
methods, as it usually requires more effort to turn the resulting network into some-
thing practical than it would take to design a practical network manually. The NLP
optimization capability of the software is widely used though, for fine-tuning the
network temperatures by exploitation of loops and stream split ratios.
Example 3.16
Determine the pinch temperatures and the minimum utility requirements for the
streams set out in the following table, for a minimum temperature difference between
the streams of 208C. Devise a heat exchanger network to achieve the maximum
energy recovery.

Stream Heat Capacity Source Target Heat

Number Type Flow Rate kW/8C Temp. 8C Temp. 8C Load kW
1 hot 40.0 180 40 5600
2 hot 30.0 150 60 1800
3 cold 60.0 30 180 9000
4 cold 20.0 80 160 1600

Solution
The problem table to find the minimum utility requirements and the pinch temperature
can be built in a spreadsheet. The calculations in each cell are repetitive, and the formula
can be copied from cell to cell using the cell copy commands. A spreadsheet template
for the problem table algorithm is available in MS Excel format in the online material at
http://books.elsevier.com/companions. The use of the spreadsheet is illustrated in
Figure 3.31 and described here.
First, calculate the interval temperatures, for DTmin ¼ 20 C
hot streams Tint ¼ Tact  10 C
cold streams Tint ¼ Tact þ 10 C
 3.17.

Project Name
Company Name Project Number Sheet 1 of 1
Address REV DATE BY APVD REV DATE BY APVD

PROBLEM TABLE ALGORITHM

Form XXXXX-YY-ZZ
1. Minimum temperature approach
HEAT EXCHANGER NETWORKS

ΔTmin 20 ⬚C

2. Stream data

Actual temperature (⬚C) Interval temperature (⬚C) Heat capacity flow Heat load
Stream No. Source Target Source Target rate CP (kW/ºC) (kW)
1 180 40 170 30 40 5600
2 150 60 140 50 30 2700
3 30 180 40 190 60 9000
4 80 160 90 170 20 1600
5 0
6 0
7 0
8 0

3. Problem table

Interval Interval temp Interval Sum CPc - sum CPh dH Cascade

(⬚C) ΔT (⬚C) (kW/ºC) (kW) (kW) (kW)
190 0 2900
1 170 20 60 1200 −1200 1700
2 170 0 60 0 −1200 1700
3 140 30 40 1200 −2400 500
4 90 50 10 500 −2900 0
5 50 40 −10 −400 −2500 400
6 40 10 20 200 −2700 200
7 30 10 −40 −400 −2300 600
8

Figure 3.31. Problem table algorithm spreadsheet.

141
142 CHAPTER 3 FUNDAMENTALS OF ENERGY BALANCES AND ENERGY UTILIZATION

Actual Temp. 8C Interval Temp. 8C

Stream Source Target Source Target
1 180 40 170 30
2 150 60 140 50
3 30 180 40 190
4 80 160 90 170

In the spreadsheet this can be done by using an IF function to determine whether

the source temperature is larger than the target temperature, in which case the stream
is a cold stream and should have DTmin =2 added.
Next, rank the interval temperatures, ignoring any duplicated values. In the
spreadsheet this is done using the LARGE function. Determine which streams occur
in each interval. For a stream to be present in a given interval, the largest stream
interval temperature must be greater than the lower end of the interval range, and the
lowest stream interval temperature must also be greater than or equal to the lower end
of the interval range. This can be calculated in the spreadsheet using IF, AND, and OR
functions. Once the streams in each interval have been determined, it is possible to
calculate the combined stream heat capacities. These calculations are not strictly part
of the problem table, so they have been hidden in the spreadsheet (in columns to the
right of the table).
The sum of CP values for the cold streams minus that for the hot streams can
then be multiplied by the interval DT to give the interval DH, and the interval DH
values can be cascaded to give the overall heat flow. The amount of heat that must
be put in to prevent the heat flow from becoming negative is the lowest value in
the column, which can be found using the SMALL function. The final column then
gives a cascade showing only positive values, with zero energy cascading at the
pinch temperature.
In the last column 2900 kW of heat have been added to eliminate the negative
values in the previous column; so the hot utility requirement is 2900 kW, and the cold
utility requirement, the bottom value in the column, is 600 kW.
The pinch occurs where the heat transferred is zero, that is, at interval number 4,
interval temperature 908C.
So at the pinch hot streams will be at
90 þ 10 ¼ 100 C
and the cold streams will be at
90  10 ¼ 80 C
Note that in the table both stream 1 and stream 4 had an interval temperature of
1708C, which led to a duplicate line in the list of ranked interval temperatures.
Strictly, this line could have been eliminated, but since it gave a zero value for the
DT, it did not affect the calculation. The programming of the spreadsheet is a lot
easier if duplicate temperatures are handled in this manner.
3.17. HEAT EXCHANGER NETWORKS 143

To design the network for maximum energy recovery, start at the pinch and match
streams, following the rules on stream heat capacities for matches adjacent to the
pinch. Where a match is made, transfer the maximum amount of heat.
The proposed network is shown in Figure 3.32.
The methodology followed in devising this network was as follows:

Above Pinch
1. CPh # CPc
2. Can match stream 1 or 2 with stream 3, but neither stream can match with
stream 4. This creates a problem, since if we match stream 1 with 3, then stream
2 will not be able to make a match at the pinch. Likewise, if we match stream 2
with 3, then stream 1 will not be able to make a match at the pinch.
3. Check the heat available in bringing the hot streams to the pinch temperature:
stream 1 DH ¼ 40:0(180  100) ¼ 3200 kW
stream 2 DH ¼ 30:0(150  100) ¼ 1500 kW
4. Check the heat required to bring the cold streams from the pinch temperature to
their target temperatures:
stream 3 DH ¼ 60:0(180  80) ¼ 6000 kW
stream 4 DH ¼ 20:0(160  80) ¼ 1600 kW
5. If we split stream 3 into two branches with CP of 40.0 and 20.0, then we can
match the larger branch with stream 1 and transfer 3200 kW, which satisfies
(ticks off) stream 1.
6. We now have two cold streams, both with CP of 20.0 and one hot stream (2)
with CP of 30.0. We need to split stream 2 into two branches. As an initial guess,
these can both have CP of 15.0. We can then match one branch of stream 2 with
the smaller branch of 4 and transfer 750 kW, and the other branch with stream
3, also for 750 kW, which then ticks off stream 2.

CP ΔH
(kW/⬚C) (kW)

180⬚C 100⬚C 100⬚C 40⬚C 40 5600

1 C
600 kW
150⬚C 100⬚C 100⬚C 60⬚C 30 2700
2

180⬚C 80⬚C 80⬚C 30⬚C

2050 kW 3200 kW 1800 kW 3 60 9000
H
750 kW 1200 kW
160⬚C H 80⬚C 4 20 1600
850 kW 750 kW

Figure 3.32. Proposed heat exchanger network for Example 3.17.

144 CHAPTER 3 FUNDAMENTALS OF ENERGY BALANCES AND ENERGY UTILIZATION

7. Include a heater on the smaller branch of stream 3 to provide the balance of

the heat required:
DHhot ¼ 6000  3200  750 ¼ 2050 kW
8. Include a heater on stream 4 to provide the balance of the heat required:
DHhot ¼ 1600  750 ¼ 850 kW

Check sum of heater duties ¼ 2050 þ 850 ¼ 2900 kW ¼ hot utility target.
Below Pinch
9. CPh $ CPc
10. Note that stream 4 starts at the pinch temperature so cannot provide any
cooling below the pinch.
11. Cannot match stream 1 or 2 with stream 3 at the pinch.
12. Split stream 3 to reduce CP.
13. Check the heat available from bringing the hot streams from the pinch tem-
perature to their target temperatures:
stream 1 DH ¼ 40:0(100  40) ¼ 2400 kW
stream 2 DH ¼ 30:0(100  60) ¼ 1200 kW
14. Check the heat required to bring the cold streams from their source temper-
atures to the pinch temperature:
stream 3 DH ¼ 60:0(80  30) ¼ 3000 kW

stream 4 is at the pinch temperature.

15. Note that stream 1 cannot be brought to its target temperature of 408C by full
interchange with stream 3, as the source temperature of stream 3 is 308C, so
DTmin would be violated. So transfer 1800 kW to one leg of the split stream 3.
16. Check temperature at exit of this exchanger:
1800
Temp out ¼ 100  ¼ 55 C, satisfactory
40
17. Provide cooler on stream 1 to bring it to its target temperature, cooling
needed:
DHcold ¼ 2400  1800 ¼ 600 kW
18. Transfer the full heat load from stream 2 to second leg of stream 3; this satisfies
both streams.
Note that the heating and cooling loads, 2900 kW and 600 kW, respectively, match
those predicted from the problem table.
Note also that in order to satisfy the pinch decomposition and the stream matching
rules, we ended up introducing a large number of stream splits. This is quite common
3.18. REFERENCES 145

in heat exchanger network design. None of the three split fractions were optimized, so
substantial savings as well as simplification of the network could be possible. For
example, loops exist between the branches of stream 3 and stream 1 and between the
branches of stream 3 and stream 2. With the current split ratios, these loops cannot be
eliminated, but with other ratios, it might be possible to eliminate one or two
exchangers.
The introduction of multiple stream splits is often cited as a drawback of the pinch
method. Stream splits can be problematic in process operation. For example, when an
oil or other multicomponent stream is heated and partially vaporized, then the stream
is a two-phase mixture. It is difficult to control the splitting of such streams to give the
required flow rate in each branch. Experienced designers usually constrain the net-
work to avoid multiple stream splits whenever possible, even if this leads to designs
that have higher than minimum utility consumption.

3.18. REFERENCES
Barnwell, J. and Morris, C. P. (1982) Hyd Proc. 61 ( July) 117. Heat pump cuts energy use.
Bloch, H. P., Cameron, J. A., Danowsky, F. M., James, R., Swearingen, J. S., and Weightman,
M. E. (1982) Compressors and Expanders: Selection and Applications for the Process
Industries (Dekker).
Bosnjakovic, F. (1935) Technische Thermodynamik (T. Steinkopff ).
Buse, F. (1981) Chem Eng, NY 88 (January 26) 113. Using centrifugal pumps as hydraulic
turbines.
Chada, N. (1984) Chem Eng, NY 91 (July 23) 57. Use of hydraulic turbines to recover energy.
Coulson, J. M., Backhurst, J., and Harker, J. H. (1999) Chem Eng. Volume 1, 6th ed.
(Butterworth-Heinemann).
Douglas, J. M. (1988) Conceptual Design of Chemical Processes (McGraw-Hill).
Dryden, I. (ed.) (1975) The Efficient Use of Energy (IPC Science and Technology Press).
Dunn, K. S. and Tomkins, A. G. (1975) Inst Mech Eng Conference on Energy Recovery in the
Process Industries, London. Waste heat recovery from the incineration of process wastes.
Dunn, R. F. and El-Halwagi, M. M. (2003) J Chem Technol Biotechnol. 78, 1011. Process
integration technology review: background and applications in the chemical process
industry.
Edmister, W. C. (1948) Pet Ref 27 (November) 129 (609). Applications of thermodynamics
to hydrocarbon processing, part XIII heat capacities.
Gundersen, T. and Naess, L. (1988). Comp and Chem Eng, 12, No. 6, 503. The synthesis of
cost optimal heat exchanger networks an industrial review of the state of the art.
Himmelblau, D. M. (1995) Basic Principles and Calculations in Chemical Engineering, 6th
ed. (Pearson).
Hinchley, P. (1975) Inst Mech Eng Conference on Energy Recovery in the Process Industries,
London. Waste heat boilers in the chemical industry.
Holland, F. A. and Devotta, S. (1986) Chem Engr, London, No. 425 (May) 61. Prospects for
heat pumps in process applications.
Holmann, E. C. (1971) PhD Thesis, University of South California, Optimum networks for
heat exchangers.
IChemE (1994) User Guide on Process Integration for Efficient Use of Energy, revised ed.
(Institution of Chemical Engineers, London).
146 CHAPTER 3 FUNDAMENTALS OF ENERGY BALANCES AND ENERGY UTILIZATION

Jenett, E. (1968) Chem Eng, NY 75 (April 8) 159, (June 17) 257 (in two parts). Hydraulic
power recovery systems.
Kenney, W. F. (1984) Energy Conversion in the Process Industries, Academic Press.
Kobe, K.A. (1958) Pet Ref. 44. Thermochemistry of petrochemicals.
Linnhoff, B. and Flower, J. R. (1978) AIChEJ 24, 633 (2 parts). Synthesis of heat exchanger
networks.
Linnhoff, B., Mason, D. R., and Wardle, I. (1979) Comp and Chem Eng. 3, 295, Under-
standing heat exchanger networks.
Linnhoff, B., Townsend, D. W., Boland, D., Hewitt, G. F., Thomas, B. E. A., Guy, A. R., and
Marsland, R. H. (1982) User Guide on Process Integration for the Efficient Use of Energy,
1st ed. (Institution of Chemical Engineers, London).
Luckenbach, E. C. (1978) U.S. 4,081,508, to Exxon Research and Engineering Co. Process
for reducing flue gas contaminants from fluid catalytic cracking regenerator.
Meili, A. (1990) Chem Eng Prog. 86(6) 60. Heat pumps for distillation columns.
Miller, R. (1968) Chem Eng, NY 75 (May 20) 130. Process energy systems.
Moser, F. and Schnitzer, H. (1985) Heat Pumps in Industry (Elsevier).
Perry, R. H. and Chilton, C. H. (eds.) (1973) Chemical Engineers Handbook, 5th ed.
(McGraw-Hill).
Perry, R. H., Green, D. W., and Maloney, J. O. (eds.) (1997) Perry’s Chemical Engineers’
Handbook, 7th ed. (McGraw-Hill).
Reay, D. A. and Macmichael, D. B. A. (1988) Heat Pumps: Design and Application, 2nd ed.
(Pergamon Press).
Santoleri, J. J. (1973) Chem Eng Prog. 69 ( January) 69. Chlorinated hydrocarbon waste
disposal and recovery systems.
Shultz, J. M. (1962) Trans ASME 84 ( Journal of Engineering for Power) ( January) 69, (April)
222 (in two parts). The polytropic analysis of centrifugal compressors.
Singh, J. (1985) Heat Transfer Fluids and Systems for Process and Energy Applications
(Marcel Dekker).
Smith, R. (2005) Chemical Process Design and Integration (Wiley).
Sterbacek, Z., Biskup, B., and Tausk, P. (1979) Calculation of Properties Using Correspond-
ing-state Methods (Elsevier).

3.19. NOMENCLATURE

Dimensions
in MLTu
A Area L2
a Constant in specific heat equation L2 T2 u1
(equation 3.13)
B Bottoms flow rate MT1
b Constant in specific heat equation L2 T2 u2
(equation 3.13)
CP Stream heat capacity flow rate ML2 T2 u1
CPc Stream heat capacity flow rate, ML2 T2 u1
cold stream
CPh Stream heat capacity flow rate, ML2 T2 u1
hot stream
Cp Specific heat at constant pressure L2 T2 u1