UMIST ©DPI 2004

Heat IntegrationA short description

with illustration case study

Department of Process Integration, UMISTManchester, UK

UMIST ©DPI 2004

UMIST ©DPI 2004

Heat Integration

HEN

Grassroot

Retrofit Analysis

60C

40C50C

100CH1

C1HE

HE

UMIST ©DPI 2004

Process Integration• Developed and pioneered at DPI UMIST

• Gradually being established in industrial

applications needs to penetrate into municipal etc

• DPI UMIST has a consortium of 26 world leading

partners in the field

• It is supported by research SW

• Latest research in combined Water & Energy savings

UMIST ©DPI 2004

Heat Integration

• Typical energy saving 15 – 45 %

• Very general – easily applicable in Power

generation, Oil refining, Petrochemicals, Food

and Drink Industry, Pulp & Paper, hospitals etc

• Typical pay-back periods from a few weeks to

16 months (decision made by the client)

• Considerably contributes to Emissions

Reduction including CO2

UMIST ©DPI 2004

Some PI Consortium Members• BP • Degussa • Mitsubishi

• Air Products • Saudi Aramco • Exon Mobil

• AspenTech • Sinopec • Norsk Hydro

• Shell • IFP • Eng of India

• CANMET • TotalFinaElf • JGC Corp

• UOP • MW Kellogg • BOC

UMIST ©DPI 2004

Demonstration Example

• Most present applications are

not grass-route but retrofits

• Considerably more difficult constrained

problem

• Economy dictates the energy saving

potential by pay-back period

UMIST ©DPI 2004

Retrofit of HEN

• Crude Distillation Unit

• Part of a Romanian refinery complex

• Designed some years ago by a well

known contractor

• Improvement of efficiency and energy

consumption & economic savings

UMIST ©DPI 2004

Introduction

Objectives

Process Process

Integration Integration

AnalysisAnalysis

Conclusions

Acknowledgement

s

PINCH ANALYSIS

SUGGESTED DESIGNS

DATA COLLECTION

SIMULATION

EXISTING PROCESS

RETROFIT ANALYSIS

Process Process

IntegratiIntegrati

on on

AnalysisAnalysis

EXISTING PROCESSEXISTING PROCESS

UMIST ©DPI 2004

Preheat TrainCrude

Oil

Kerosene

Atmospheric Tower

Medium Naphtha

Vapour

Naphtha Stabiliser Light Naphtha

LPG (C2 - C5)

Vapour

Vacuum Residue

HVGO

LVGO

Vacuum Tower

Vapour

LAGO

HAGO

Diesel

Atmospheric Residue

Denaphtha Tower

Vapour

Denaphtha Oil

Naphta

Steam

Kerosene

UMIST ©DPI 2004

Introduction

Objectives

Process Process

Integration Integration

AnalysisAnalysis

Conclusions

Acknowledgement

s

PINCH ANALYSIS

SUGGESTED DESIGNS

DATA COLLECTION

SIMULATION

EXISTING PROCESS

SIMULATION

RETROFIT ANALYSIS

SIMULATION

Process Process

IntegratiIntegrati

on on

AnalysisAnalysis

UMIST ©DPI 2004

• Plant measurements & HYSYS

• Peng-Robinson property package

• Main source of data

• Existing HEN

• Energy consumption

UMIST ©DPI 2004

112.8C

92.4C

162.8C

158.1C

315.6C

262.9C

217.8C

170.8C

90C

90C

70C

40C

50C

210C

90C

90C

20C

211.3C

158.3C

220C

348C

110C

350C

370C

162.8C

63.2C

144C

315C

240.1C

291.7C

353.2C

63.6C

69.1C

107.2C

60C

150C

76.8C131.1C

261.4C

1

26

2

7

10

13

25

21

23 24

22

18

15

12

9

31

32

33

27

30

29

28

3

4

5 6

8

11

14

16 17

19 16 14 11 8 46

5

17 3

H1

H2

H3

H4

H5

H6

H7

H8

H9

H14

H13

H12

H10

H11

C1

C2

C3

C4

C5

C6

19

UMIST ©DPI 2004

112.8C

92.4C

162.8C

158.1C

315.6C

262.9C

217.8C

170.8C

90C

90C

70C

40C

50C

210C

90C

90C

20C

211.3C

158.3C

220C

348C

110C

350C

370C

162.8C

63.2C

144C

315C

240.1C

291.7C

353.2C

63.6C

69.1C

107.2C

60C

150C

76.8C131.1C

261.4C

1

26

2

7

10

13

25

21

23 24

22

18

15

12

9

31

32

33

27

30

29

28

11238.9

6797.2

538.9

20027.8

6758.3 6630.3

15113.9

1673.0 1228.6 230.1

1410.5 1614.2 320.0

3293.9 1971.7

1652.8 452.2 177.1

2767.5 833.3 788.9

2959.4 1057.5 1207.5

13326.9

4491.7

2702.2 1688.6

52480.6

1563.6

14875.0

3

4

5 6

8

11

14

16 17

19 16 14 11 8 46

5

17 3

H1

H2

H3

H4

H5

H6

H7

H8

H9

H14

H13

H12

H10

H11

C1

C2

C3

C4

C5

C6

16349.4

19

AC

AC

AC

AC

AC

AC

AC

H

H

H

H

CW = 38,293 kW

AC = 8,677 kW

H = 73,410 kW

CW

CW

CW

CW

CW

CW

CW

CW

UMIST ©DPI 2004

Introduction

Objectives

Process Process

Integration Integration

AnalysisAnalysis

Conclusions

Acknowledgement

s

PINCH ANALYSIS

SUGGESTED DESIGNS

DATA COLLECTION

SIMULATION

EXISTING PROCESS

DATA COLLECTION

RETROFIT ANALYSIS

DATA COLLECTIONProcess Process

IntegratiIntegrati

on on

AnalysisAnalysis

UMIST ©DPI 2004

Name No. TS

(C)TT

(C)m

(kg/h)

H(kW)

MCP(kW/ C)

C2_cond H1 112.8 63.6 94,870 11,238 228.4

C3_cond H2 92.4 69.1 66,510 6,797 291.7

Light_nap H3 162.8 107.2 14,370 485 9.5

P/A naph. H4 158.1 60.0 350,000 20,027 204.1

P/A keros H5 261.4 150.0 180,000 13,383 120.1

C1_cond H6 131.1 76.8 81,440 15,113 278.3

Kerosene H7 170.8 50.0 45,000 3,111 25.7

Diesel H8 217.8 40.0 32,000 3,333 18.7

LAGO H9 262.9 70.0 44,000 5,247 27.2

HAGO H10 315.6 90.0 16,000 2,277 10.1

LVGO H11 240.1 90.0 48,000 4,371 29.1

UMIST ©DPI 2004

Name No. TS

(C)TT

(C)m

(kg/h)

H(kW)

MCP(kW/ C)

HVGO_P/A H12 291.7 210.0 216,500 12,205 149.4

HVGO_F H13 291.7 90.0 73,500 9,369 46.4

Vac_resid H14 353.2 90.0 105,700 17,652 67.1

Raw crude C1 20.0 220.0 33,370 55,555 277.8

C1_feed C2 211.3 348.0 408,300 52,480 383.9

C3_reb C3 158.3 162.8 94,870 6,758 1,501.8

C5_feed C4 315.3 370.0 80,510 14,875 271.9

Steam C5 144.0 350.0 214,500 1,563 7.6

C3_feed C6 63.2 110.0 13,138 991 21.2

SG_1&2 C7 98.0 144.1 8,739 5,726 124.2

SG_3 C8 98.0 195.9 106,900 13,326 136.1

UMIST ©DPI 2004

Exchanger No. Name Area (m2)

1 C2 condenser 1,029.5

2 C3 condenser 720

3 SE- 4 412

4 SE- 8 658

5 C3 reboiler 760

6 SE- 13 620

7 C1 condenser 1,454.5

8 SE- 9 329

9 AE- 3 78.4

10 SE- 10 200

.

...

.

.

Exchanger

Data

UMIST ©DPI 2004

Economic Data

HE : HEC($) = K1 + K2 AK3

T < 200C (CS) : HEC($) = 33,641 + 819 A0.78

T > 200C (SS) : HEC($) = 33,641 + 1,795 A0.78

Utilities

Cooling water: 9.23 $/kW

y

Cooling air: 8.31 $/kW y

Fuel gas: 57.4 $/kW y

1996 dataNelson-Farrar

Cost Index

UMIST ©DPI 2004

Introduction

Objectives

Process Process

Integration Integration

AnalysisAnalysis

Conclusions

Acknowledgement

s

PINCH ANALYSIS

SUGGESTED DESIGNS

DATA COLLECTION

SIMULATION

EXISTING PROCESS

PINCH ANALYSIS

RETROFIT ANALYSIS

PINCH ANALYSIS

Process Process

IntegratiIntegrati

on on

AnalysisAnalysis

UMIST ©DPI 2004

0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00

Tmin [C]

0.25E+07

0.35E+07

0.45E+07

0.55E+07

0.65E+07

0.75E+07

0.85E+07

0.95E+07

0.11E+08

Total Cost

Capital Cost

Operating Cost

($/y)Optimum TMIN

UMIST ©DPI 2004

6.66E+06

6.68E+06

6.70E+06

6.72E+06

6.74E+06

6.76E+06

6.78E+06

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

Tmin(C)

($/y

)

Optimum tmin

Total Cost

UMIST ©DPI 2004

0.0 4 104 8 104 1.2 105 1.6 105

Enthalpy [kW]

50.0

100.0

150.0

200.0

250.0

300.0

350.0

400.0

T(

C)

QH,MIN = 55,553 kW

QC,MIN = 29,881 kW

Composite Curves

UMIST ©DPI 2004

Introduction

Objectives

Process Process

Integration Integration

AnalysisAnalysis

Conclusions

Acknowledgement

s

PINCH ANALYSIS

SUGGESTED DESIGNS

DATA COLLECTION

SIMULATION

EXISTING PROCESS

RETROFIT ANALYSIS

Process Process

IntegratiIntegrati

on on

AnalysisAnalysis

RETROFIT ANALYSISRETROFIT ANALYSIS

UMIST ©DPI 2004

Network Pinch Method

• Pinching matches bottleneck

• How to overcome pinching matches?

UMIST ©DPI 2004

Network Pinch Method

DIAGNOSIS STAGE

New Modifications

OPTIMISATION STAGE

Energy - Capital Cost Trade-off

Existing HEN

Suggested Design

UMIST ©DPI 2004

(8)

2nd RESEQUENCE

HE16, stream C1

(9)

1st NEW HE

HE34: H14 – C2

(10)

2nd NEW HE

HE35: H12 – C2

(11)

3th NEW HE

HE36: H11 - C1

(7)

1st RESEQUENCE

HE4, stream C1

(12)

1st NEW HE

HE34: H14 – C2

y

(13)

2nd NEW HE

HE35: H12 – C2

(14)

3th NEW HE

HE36: H4 - C1

(3)

3th REPIPING

HE16: H10 H11

(4)

1st NEW HE

HE34: H13 - C1

(6)

3th NEW HE

HE36: H7 - C1

(1)

1st REPIPING

HE8: H7 H14

(2)

2nd REPIPING

HE8: C1 C2

(5)

2nd NEW HE

HE35: H5 - C2

EXISTING

HEN

UMIST ©DPI 2004

Introduction

Objectives

Process Process

Integration Integration

AnalysisAnalysis

Conclusions

Acknowledgement

s

PINCH ANALYSIS

SUGGESTED DESIGNS

DATA COLLECTION

SIMULATION

EXISTING PROCESS

SUGGESTED DESIGNS

RETROFIT ANALYSIS

SUGGESTED DESIGNS

Process Process

IntegratiIntegrati

on on

AnalysisAnalysis

UMIST ©DPI 2004

(7)

1st RESEQUENCE

HE4, stream C1

EXISTING

HEN

UMIST ©DPI 2004

112.8C

92.4C

162.8C

158.1C

315.6C

262.9C

217.8C

170.8C

90C

90C

70C

40C

50C

210C

90C

90C

20C

211.3C

158.3C

220C

348C

110C

350C

370C

162.8C

63.2C

144C

315C

240.1C

291.7C

353.2C

63.6C

69.1C

107.2C

60C

150C

76.8C131.1C

261.4C

1

26

2

7

10

13

25

21

23 24

22

18

15

12

9

31

32

33

27

30

29

28

3

4

5 6

8

11

14

16 17

19 16 14 11 846

5

17 3

H1

H2

H3

H4

H5

H6

H7

H8

H9

H14

H13

H12

H10

H11

C1

C2

C3

C4

C5

C6

19

4

4

UMIST ©DPI 2004

OPTION IIn need of further study

Payback Time 1 monthsSavings = 114,190 $/y

(9)

1st NEW HE

HE34: H14 – C2

(7)

1st RESEQUENCE

HE4, stream C1

EXISTING

HEN

UMIST ©DPI 2004

112.8C

92.4C

162.8C

158.1C

315.6C

262.9C

217.8C

170.8C

90C

90C

70C

40C

50C

210C

90C

90C

20C

211.3C

158.3C

220C

348C

110C

350C

370C

162.8C

63.2C

144C

315C

240.1C

291.7C

353.2C

63.6C

69.1C

107.2C

60C

150C

76.8C131.1C

261.4C

1

26

2

7

10

13

25

21

23 24

22

18

15

12

9

31

32

33

27

30

29

28

3

4

5 6

8

11

14

16 17

19 16 14 11 846

5

17 3

H1

H2

H3

H4

H5

H6

H7

H8

H9

H14

H13

H12

H10

H11

C1

C2

C3

C4

C5

C6

19

34

34

UMIST ©DPI 2004

OPTION IICapital Investment =

133,983 $Payback Time = 4 months

Savings = 320,610 $/y

OPTION IIn need of further study

Payback Time 1 monthsSavings = 114,190 $/y

(9)

1st NEW HE

HE34: H14 – C2

(10)

2nd NEW HE

HE35: H12 – C2

(7)

1st RESEQUENCE

HE4, stream C1

EXISTING

HEN

UMIST ©DPI 2004

112.8C

92.4C

162.8C

158.1C

315.6C

262.9C

217.8C

170.8C

90C

90C

70C

40C

50C

210C

90C

90C

20C

211.3C

158.3C

220C

348C

110C

350C

370C

162.8C

63.2C

144C

315C

240.1C

291.7C

353.2C

63.6C

69.1C

107.2C

60C

150C

76.8C131.1C

261.4C

1

26

2

7

10

13

25

21

23 24

22

18

15

12

9

31

32

33

27

30

29

28

3

4

5 6

8

11

14

16 17

19 16 14 11 846

5

17 3

H1

H2

H3

H4

H5

H6

H7

H8

H9

H14

H13

H12

H10

H11

C1

C2

C3

C4

C5

C6

19

34

34

35

35

UMIST ©DPI 2004

OPTION IICapital Investment =

133,983 $Payback Time = 4 months

Savings = 320,610 $/y

OPTION IIICapital Investment =

648,803 $Payback Time = 10 months

Savings = 495,440 $/y

OPTION IIn need of further study

Payback Time 1 monthsSavings = 114,190 $/y

(9)

1st NEW HE

HE34: H14 – C2

(10)

2nd NEW HE

HE35: H12 – C2

(11)

3th NEW HE

HE36: H11 - C1

(7)

1st RESEQUENCE

HE4, stream C1

EXISTING

HEN

UMIST ©DPI 2004

112.8C

92.4C

162.8C

158.1C

315.6C

262.9C

217.8C

170.8C

90C

90C

70C

40C

50C

210C

90C

90C

20C

211.3C

158.3C

220C

348C

110C

350C

370C

162.8C

63.2C

144C

315C

240.1C

291.7C

353.2C

63.6C

69.1C

107.2C

60C

150C

76.8C131.1C

261.4C

1

26

2

7

10

13

25

21

23 24

22

18

15

12

9

31

32

33

27

30

29

28

3

4

5 6

8

11

14

16 17

19 16 14 11 846

5

17 3

H1

H2

H3

H4

H5

H6

H7

H8

H9

H14

H13

H12

H10

H11

C1

C2

C3

C4

C5

C6

19

34

34

35

35

36

36

UMIST ©DPI 2004

OPTION IICapital Investment =

133,983 $Payback Time = 4 months

Savings = 320,610 $/y

OPTION IIICapital Investment =

648,803 $Payback Time = 10 months

Savings = 495,440 $/y

OPTION IV Capital Investment =

829,367 $Payback Time = 11 months

Savings = 586,190 $/y

OPTION IIn need of further study

Payback Time 1 monthsSavings = 114,190 $/y

(9)

1st NEW HE

HE34: H14 – C2

(10)

2nd NEW HE

HE35: H12 – C2

(11)

3th NEW HE

HE36: H11 - C1

(7)

1st RESEQUENCE

HE4, stream C1

EXISTING

HEN

UMIST ©DPI 2004

100,000

150,000

200,000

250,000

300,000

350,000

400,000

450,000

500,000

550,000

600,000

2 4 6 8 10 12 14 16 18

Payback Time (months)

Uti

lity

Cost

Savin

g (

$/y

)

Option IIIOption II

Option V

Option I

Option IV

UMIST ©DPI 2004

112.8C

92.4C

162.8C

158.1C

315.6C

262.9C

217.8C

170.8C

90C

90C

70C

40C

50C

210C

90C

90C

20C

211.3C

158.3C

220C

348C

110C

350C

370C

162.8C

63.2C

144C

315C

240.1C

291.7C

353.2C

63.6C

69.1C

107.2C

60C

150C

76.8C131.1C

261.4C

1

26

2

7

10

13

25

21

23 24

22

18

15

12

9

31

32

33

27

30

29

28

3

5 6

8

11

14

16 17

19 16 14 11 86

5

17 3

H1

H2

H3

H4

H5

H6

H7

H8

H9

H14

H13

H12

H10

H11

C1

C2

C3

C4

C5

C6

19

35

35

36

36

34

34

4

4

UMIST ©DPI 2004

OPTION IV - SUGGESTED DESIGN

• 1 Re-sequence + 3 New HE

• Utility savings

• Hot utility = 12+%

• Cold utility = 19+%

• Emissions reduction (9 MW)

• Capital Investment = 830,000 US$

• Payback Time < 10 months

UMIST ©DPI 2004

PINCH ANALYSIS

SUGGESTED DESIGNS

DATA COLLECTION

SIMULATION

EXISTING PROCESS

RETROFIT ANALYSIS

EXISTING PROCESSEXISTING PROCESS

DATA COLLECTIONDATA COLLECTION

PINCH ANALYSISPINCH ANALYSIS

SIMULATIONSIMULATION

SUGGESTED DESIGNSSUGGESTED DESIGNS

RETROFIT ANALYSISRETROFIT ANALYSIS

•Network Pinch Method

•Diagnosis Stage

•Optimisation Stage

•Different Options (4)

•Suggested Topology

•1 Re-sequencing. + 3 New HE

•Savings

•Hot utility = 12+%

•Cold utility = 19+%

•Emissions reduction (9 MW)

•Payback Time 10 months

UMIST ©DPI 2004

www.dcs.vein.hu/pres2004