Process integration and optimization

(ChEg5221)

By

AMARE F. (MSc. In Process Engineering)

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 2. Process integration
Definition

Integration means combining needs/tasks of opposite kinds, so that saving can

be obtained.

Example of integration in process industries are;

 Heat integration – cooling and heating

 Power integration – expansion and compression (mechanical energy)

 Chemical integration – by product use for raw material for other.

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 Cont…

 Equipment integration – multiple phenomena (reaction, separation and heat

exchanger are integrated in the same pieces of equipment)

Process integration is a systematic and general methods for the designing

integrated production systems, ranging from individual processes to total site,
with special emphasis on the efficient use of energy and reducing environmental
effects.

Integration of any process leads to many useful outcomes like saving energy,
minimize logistics and better economy etc

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 Cont…

Process integration also define as a methodology for analysis, design and optimization of
material and energy related production systems.

Process integration may be categorized as follows;

Process integration

Mathematical optimization pinch technology

Thermal pinch material integration

The goals of process integration are;

 To minimize the generation of emission and waste

 To integrate the use of material and energy 4

 •

2.1 Pinch Technology/ Pinch Analysis

• The term pinch technology was introduced to represent a new set of thermodynamically based method

that guarantee minimum energy level in design of heat exchanger.

• Pinch Technology provides a systematic methodology for energy saving in processes and total sites.

• It is a methodology for minimizing energy consumption of a process by calculating thermodynamically

feasible energy target.

• It is also known as process integration, heat integration or energy integration.

• Pinch analysis is a systematic method based on thermodynamic principles to achieve utility saving by

better process heat integration, maximizing heat recovery and reduce the external utility loads (cooling

water and hot steam). 5

 Cont…

Generally, the main aim of pinch analysis is to achieve financial saving by using
better process integration.

Key steps of pinch technology/analysis

There are four key steps of pinch analysis in the design of heat recovery systems
for both new and existing processes.

1. Data extraction: involves collecting data for the process and utility system.

2. Targeting: establishes targets for design in terms of energy, number of units,

area, cost etc. for best performance.
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 Cont…

3. Design: establishes an initial heat exchange network (HEN)

4. Optimization: where in the initial design is simplified and improved

economically.

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 Cont…

Name of Supply Target Specific Heat Heat load

stream temperature (oC) temperature(o capacity (kw/oC) (kw)
C)
Hot -1 150 50 3 -300
Hot-2 170 169 360 -360
Cold-1 30 150 3 360
Cold -2 30 40 30 300

(-ve) sign indicates heat to be given by a stream and (+ve) sign indicates heat
to be received by a given stream. 8
 Cont…

• It appears from the table that the whole system is in thermal equilibrium and
thus energy conservation is not possible. Whereas, from the following figure it is
clear that internal heat exchanger is possible up to the extent of 300kw and cold
utility can be eliminated.

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 Cont…

1. Hot and cold composite curves

Composite curves are temperature- enthalpy (T-H) profiles of heat
available in the process (through the hot composite curve) and heat
demand in the process (through the cold composite curves) with the
help of graphical representation.
The combined hot and cold utility curve helps in plant layout as it
indicates which hot stream should be close to which cold stream for
minimum piping.

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Identification of hot and cold utility stream
Hot stream – are those that must be cooled (heat sources)
Cold stream – are those that must be heated (heat sink)
Utility stream – are those used to heat or cool process stream when
heat exchanger between process streams is not practical or
economically.
The development and application of pinch analysis can be illustrated by
considering the process of integrating utilization of energy between
two process streams.

 The initial temperature is termed as supply temperature (Ts) 11

 Cont…
• 
 The final temperature is termed as target temperature (Tt)

Heat capacity flow rate of each stream is shown as CP (kw/oC)

CP = mass flow rate* specific heat capacity (Cp)

The heat load of one stream also calculated as

ΔH = CP (Tt-Ts) or Cp (Tt-Ts)

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 2.1.1 The Principle of Pinch Technology

• 
• The point where Tmin is observed in the T-H graph is known as Pinch
point.

• Once the pinch has been identified, it is possible to consider the

process as two separate systems: one above and one below the pinch,
as shown in the Figure below.
•The system above the pinch requires a heat input and is therefore a
net heat sink. Below the pinch, the system rejects heat and so is a net
heat source.
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To summarize and to understanding the principle of pinch gives

three rules that must be obeyed in order to achieve the minimum

energy targets for a process:

 Heat must not be transferred across the pinch

 There must be no external cooling above the pinch

 There must be no external heating below the pinch

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 Cont…

Consider two stream problem for prediction of hot and cold utility demand.

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 Cont…

Our purpose here is to find out the followings

1. The out let temperature of the hot and cold streams.
2. The amount of external utility required (hot and cold).
3. The amount heat recovery.
solution
First of all, extract the data from the given flow sheet
Name of stream Supply Target Heat flow rate Heat load (kw)
temperature temperature CP (kw/oC)
(oC) (oC)
Hot-1 210 50 1.5 -240
Cold-1 90 160 3 210
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 Cont…
• 
plot the hot and cold composite curves by take 10oC minimum
temperature difference (ΔTmin).

Note that, at (ΔTmin) equals to zero there is no heat transfer takes

place because the area of heat transfer is approaches to infinite.
Q = UA ΔTmin and where A = as ΔTmin A

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• 
 The out let temperature of hot stream is 100oC and the out let
temperature of cold stream is 145oC.
The amount of heat recovery (Qrec) = Hhot – Qcold

= (240-75) kw = 165kw Or

The amount of heat recovery (Qrec) = Hcold – Qhot

= (240-75) kw = 165kw
what we observe from the T-H curve?

1. As ΔT increase, the cold and hot external utility demand

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2. As ΔTmin decrease, both cold and hot external utility demand
decrease.
3. As ΔTmin increase heat recovery decrease and as ΔTmin decrease
heat recovery increase.
For example
As ΔTmin change from 10oC to 20oC the external cold utility changes
from 75kw to 90kw and external hot utility changes from 45kw to
60kw.
As ΔTmin change from 10oC to 20oC the heat recovery changes from
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Example 2
four stream problem for load integration and utility prediction at
ΔTmin = 10oC using the following extracted data. 22
 Name of Supply Target Heat flow rate Heat
stream temperature temperature CP (kw/oC) load
(oC) (oC) (kw)
Hot-1 140 50 2 -180
Hot-2 90 40 6 -300
Cold-1 30 150 2 240
Cold-2 70 125 3 165

Draw the composite curve and determine the followings

a. The heat recovery (Qrec.)

b. The minimum external hot and cold utility required (Q and Q )

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Solution
First draw the hot composite curve and to draw the
curve we have to put the temperature in descending
order.

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Second, draw the cold composite curve and to draw the curve we
have to use the same fashion with the above.

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Home-work

1. Extract the data from the flow sheet below and determine the pinch

temperature, the minimum utility requirements and maximum heat recovery for

the process. Take the minimum change of temperature 20 oC.

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2.
•   Heat Integration Using Problem table method
Problem table method is a numerical method for determining the
pinch temperature and the minimum utility requirements.

The Procedures we have to follow in problem table method are:

1. Convert the actual stream temperatures (Tactual) into interval

temperature (Tinterval) by subtracting half of the ΔTmin from the hot
stream temperatures, and by adding half to the cold stream
temperatures: hot stream
cold stream Tint =
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• 
2. Note any duplicated interval temperature.

3. rank the interval the temperature in order of magnitude, show the

duplicated temperature only once in the order.

4. Carry out a heat balance for the streams falling with in each

temperature interval: For the nth interval:

=net heat required in the nth interval

= sum of the heat capacities of all the cold streams in the interval
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• 
= sum of the heat capacities of all the hot streams in the interval
= interval temperature difference ()
5. "Cascade “the heat surplus from one interval to the next down the
column of interval temperatures
6. Introduce just enough heat to the top of the cascade to eliminate
all the negative values.
The heat introduced to the cascade is the minimum hot utility
requirement and the heat removed at the bottom is the minimum
cold utility required.
The pinch occurs where the heat flow in the cascade is zero.
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Example 3

Integrate the heat of streams in the flow sheet given below and find
the followings using problem table method;

a. Pinch temperature

b. The minimum external utilities (hot and cold)

c. The maximum heat recovery

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Solution
First, Extract the data from the given flow sheet

Stream type Ts (k) Tt(k) CP (kw/k) H (kw)

Hot-1 460 350 300 33,000

Hot-2 400 300 500 50,000

Cold-1 420 490 600 42,000

Cold-2 320 390 200 14,000

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• 
Step-1: convert the actual stream temperature into interval temperature:

hot stream

cold stream Tint =

Ts int. Tt int.

455 345

395 295

425 495

325 395

Step-2: indicate any duplicated interval temperature. 35

Step-3: Rank the interval temperature and construct problem table.

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• 
Therefore, from table above we got;

a. Pinch temperature (Tp-inch) = 425K

b. Minimum external cold utility (Qc-min) = 60,000kw

and minimum external hot utility (Qh-min) = 33,000kw

C. Qrec= - Qc-min = (33,000 + 50,000) - 60,000 = 23,000Kw

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