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
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