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PURPOSE
The intention of this Module is to provide a general view of the available techniques for the retrofit and operability analysis of existing heat and mass exchange networks.
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PRE-REQUISITES
In order to achieve a better understanding of the contents of this Module, the student or reader are required to possess a background of specific areas of chemical engineering such as classic thermodynamic, mass transfer and heat transfer. These subjects are part of basic science of chemical engineering and must be contained into its curricula. A Process Introduction Module review prior to this Module is recommended too. In such, an overview of Pinch Technology and Heat Recovery Network can be found to help you begin with the Network Pinch Analysis subject.
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AUDIENCE TARGET.
The Network Pinch Module is addressed to last year bachelor degree and MSc students in chemical engineering. Particularly it will be useful for practicing engineers and even teachers of plant design and pollution prevention courses.
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STRUCTURE:
TIER I. FUNDAMENTALS TIER II. CASE STUDIES TIER III. OPEN ENDED PROBLEMS
TIER I
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TIER I: FUNDAMENTALS
1. HEAT RECOVERY NETWORKS (HEN). 2. STEADY STATE SIMULATION of HENs. 3. OPERABILITY ANALYSIS of HENs. 4. RETROFIT of HENs. 5. MASS EXCHANGE NETWORKS (MEN). 6. OPERABILITY ANALYSIS of MENs.
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1.1 Introduction.
One of the main advantages of Pinch Technology over conventional design methods is the ability to set energy and capital cost targets for an individual process or for an entire production site ahead of design. Therefore, ahead of identifying any specific project, we know the scope for energy savings and investment requirements.
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Most industrial processes involve transfer of heat either from one process stream to another process stream (interchanging) or from an utility stream to process stream.
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In the present energy crisis scenario all over the world, the target of any industrial process designer is to maximizes the process-toprocess heat recovery and to minimize the utility (energy) requirements.
Heat Recovery
Energy requirements
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To meet the goal of maximize energy recovery or minimum energy requirement (MER) an appropriate heat exchanger network (HEN) is required.
2 1 2 4 6
Cold water
Steam
7
320 528.0 412.8 341.1
5
3
3
6
86.3 217.5
Steam
H H H H C C C
451.4 427.4 505.6
1 2 4 6
Cold water
H
16.2 22.4 412.8
5 4
2
341.1 Hot Stream Cold Stream
H Heater
C Cooler
Heat exchanger
a) Traditional design: Cost operating 250,838 $/year Cost capital 4,937 $/year
b) Technology Pinch approach: Cost operating 24,077.00 $/year Cost capital 4,180.00 $/year
Fig. 1.1 (a) The non-integrated solution, (b) The optimally integrated solution Reference.
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Identification of the hot, cold and utility streams in the process. Thermal data extraction for process and utility stream. Selection of Initial TMIN value. Construction of Composite Curves and Grand Composite Curve.
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Tin
Tout
H1
Cold streams: are those that must be heated (Tout > Tin).
Tin Tout
C1
Utility streams: are used to heat or cool process stream, when heat exchange between process stream is not practical or economic. A number of different hot utilities (steam, hot water, flue gas, etc) and cold utilities (cooling water, air, refrigerant, etc.) are used in industry.
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Stream Number 1 2 3 4
Target Supply Temperature Temperature (oC) (oC) 60 270 220 160 205 160 70 210
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For a given value of heat transfer load (Q) the selection of TMIN values has implications for both capital and energy costs.
TMIN
A few values of based Linnhoff Marchs application experience are tabulated below for shell and tube heat exchangers.
No
1 2 3 4
Industrial Sector
Oil Refining Petrochemical Chemical Low Tem perature Process
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Composite Curves
Composite Curves consist of temperature (T) - Enthalpy (H) profiles of heat availability in the process (the Hot Composite Curve) and heat demands in the process (the Cold Composite Curve) together in a graphical representation. In general any stream with a constant heat capacity (CP) value is represented on a diagram by a straight line running from stream supply temperature to stream target temperature. When there are a number of hot and cold composite curves simply involves the addition of the enthalpy changes of the stream in the respective temperature intervals. An example of hot composite curves is shown in Fig. 1.2
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T
0 =6
0
T
CP =
1000
CP
CP
CP
20
80 = 0 +2 = 60
=2
CP =
3000
3000
1000
4000
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A complete hot or cold composite curves consists of a series of connected straight lines, each change in slope represents a change in overall hot stream heat capacity flow rate (CP).
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T
PINCH
TMIN
QC,MIN
H
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Fig. 1.3 Energy targets and the pinch with Composite Curves.
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Temperature
QH, MIN
Hot Composite Curve
PINCH
Process to process Heat Recovery Potential Cold Composite Curve
TMIN
QC, MIN
Cold Utilities
Enthalpy Fig. 1.4 Combined Composite Curves. At a particular TMIN value, the overlap shows the maximum possible scope for heat recovery within the process. The hot end and cold end overshoots indicate minimum hot utility requirement (QH,MIN) and minimum cold utility requirement (QC,MIN), of the process for the chosen TMIN. Thus, the energy requirement for a process is supplied via process to process heat exchange and/or exchange with several utility levels (steam levels, refrigeration levels, hot oil circuit, furnace flue gas, etc.)
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Stream No. And Type (1) Cold (2) Hot (3) Cold (4) Hot
2 3 4 5
Fig. 1.4 Grid representation of hot and cold streams. Knowing the stream population in each interval (from Fig. 1.8), enthalpy balances can easily be calculated for each according to:
(1.2)
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HI (kW)
- 60 - 2.5 + 82.5 - 75 + 15
SURPLUS OR DEFICIT
SURPLUS SURPLUS DEFICIT SURPLUS DEFICIT
T5 = 55 oC
5
T6 = 25 oC Fig. 1.5 Example for Table Problem Algorithm. The last column in Fig. 1.5 indicates whether an interval is in heat surplus or heat deficit. It would therefore be possible to produce a feasible network design based on the assumption that all surplus intervals rejected heat to cold utility , and all deficit intervals took heat from hot utility. However, this would not be very sensible because it would involve rejecting and accepting heat at inappropriate temperatures.
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We now, however, exploit a key feature of the temperature intervals Namely, any heat available in interval i is hot enough to supply any duty in interval i +1. This is shown in Figure 1.6 (a), where interval 1 and 2 are used as an illustration. Instead of sending the 60 kW of surplus heat from interval 1 into cold utility, it can be sent down into interval 2. It is therefore possible to set up a heat cascade as shown in the Figure 1.6 (b).
165 Oc 1 145 Oc 2 140 Oc 3 85 Oc 4 55 Oc 5 25 Oc H = -75 kW 55 Kw H = + 15 kW 40 Kw TO COLD UTILITY (a) INFEASIBLE 5 FROM HOT UTILITY 0 Kw H = - 60 kW 60 Kw H = - 2.5 kW 62.5 Kw H = + 82.5 kW - 20 kW QH,MIN 4 3 2 1 FROM HOT UTILITY 20 Kw H = - 60 kW 80 Kw H = - 2.5 kW 82.5 Kw H = + 82.5 kW 0 Kw H = -75 kW 75 Kw H = + 15 kW QC,MIN 60 Kw TO COLD UTILITY (b) PINCH, Q,H, MIN, QC, MIN
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Fig. 1.6 The heat cascade principle - target prediction by problem table analysis.
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FROM HOT UTILITY 20 Kw 1 2 H = - 60 kW 80 Kw H = - 2.5 kW 82.5 Kw 3 H = + 82.5 kW 0 Kw 4 H = -75 kW 75 Kw 5 H = + 15 kW 60 Kw TO COLD UTILITY Fig. 1.6 (b) (Repeat) PINCH, Q,H, MIN, QC, MIN
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Interval temperature
QH,MIN
H1
GCC TH1
H2
TH2
TPinch
C2 TC2
QC,MIN
C1
Enthalpy
TC1
Fig. 1.7 Grand Composite Curve. Figure 1.7 shows that it is not necessary to supply the hot utility at the top temperature level. The GCC indicates that we can supply hot utility over two temperature levels TH1 (HP steam) and TH2 (LP steam). Recall that, when placing utilities in the GCC, intervals, and not actual utility temperatures, should be used. The total minimum hot utility requirement remains the same: QH,MIN = H1 + H2. Similarly, QC,MIN = C1 + C2. The points TH2 and TC2 where the H2 and C2 levels touch the GCC are called the Utility Pinches. The shaded green pockets represents the process-to-process heat exchange. 31
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Summarizing
Composite curves give conceptual understanding of how energy targets can be obtained. The Problem Table gives the same results (including the Pinch location) more easily. Energy targeting is a powerful design and process integration aid.
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Estimation of minimum energy costs. Estimation of Heat Exchanger Network (HEN) Capital Cost Target. Estimation of Optimum TMIN value by Energy-Capital Trade Off. Estimation of Practical Targets for HEN Design.
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Area = Q / U x TLM
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The composite curves can be divided into a set of adjoining enthalpy intervals such that within each interval , the hot and cold composite do not change slope. Here the heat exchange is assumed to be vertical (pure counter-current heat exchange). The hot streams in any enthalpy interval, at any point, exchanges heat with the cold streams at the temperature vertically below it. The total area of the HEN (AMIN) is given by the equation following
(1.5)
i j where i denotes the ith enthalpy and interval j denotes jth stream, TLM denotes LMTD in the ith interval, and A1 + A2 + A3 ++ Ai is shown in the Figure 1.8
T Enthalpy Intervals
A1 A2 A3 A4
A5
H
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The actual HEN Total Area required is generally within 10% of the area target as calculated by Eq, (1.5). With inclusion of temperature correction factors area targeting can be extended to non counter-current heat exchange as well.
(1.6)
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The target for the minimum surface area (AMIN) and the number of units (NMIN) can be combined together with the heat exchanger cost law to determine the targets for HEN capital cost (CHEN). The capital cost is annualized using an annualization factor that takes into account interest payments on borrowed capital. The equation used for calculation the total capital cost and exchanger cost law is given in equation 1.6.
(1.7)
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Annualized Cost
Total Cost
t Cos y g r Ene
Optimum TMIN
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So what is the significance of the pinch temperature? The pinch divide the process into two separate systems each of which is in enthalpy balance with the utility. The pinch point is unique for each process. Above the pinch, only the hot utility is required. Below the pinch, only the cold utility is required. Hence, for an optimum deign, no heat should be transferred across the pinch. This is known as the key concept in Pinch Technology.
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The decomposition of the problem at the pinch turns out to be very useful when it comes to network design (Linnhoff and Hindmarsh, 1982).
Zero Flow in Pinch
QH,MIN
QH,MIN
QC,MIN H QC,MIN H
To summarize, pinch technology gives three rules that form the basis for practical network design: 1 No external heating below the pinch. 2 No external cooling above the pinch. 3 No heat transfer across the pinch. Violations of any of the above rules results in higher energy requirements than the minimum requirements theoretically possible.
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Steam
Feed
25 oC 30 oC
1 2
140 oC
200 oC 200 oC
120 oC 100 oC
Reactor
170 oC
100 oC
30 oC
Cooling
Sep. Drum
Crude Product
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1 H H 1
120 oC
100 oC
30 oC
25 oC 100 oC 30 oC
FEED RECYCLE
Fig. 1.13 Heat exchanger network in the Grid representation. The advantage of this representation is that the heat exchange matches 1 and 2 (each represented by two circles joined by a vertical line in the grid) can be placed in either order without redrawing the stream system. In flowsheet representation, if it were desired to match recycle against the hottest part of the reactor effluent, the stream layout would have to be redrawn. Also, the grid represent the countercurrent nature of the heat exchange, making it easier to check exchanger temperature feasibility. Finally the pinch is easily represented represented on the flowsheet. in the grid, whereas it cannot be
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2 4
90 oC 90 oC 80 oC
60 oC 30 oC 20 oC
135 oC 140 oC
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Above the pinch all streams must be brought to pinch temperature by interchange against cold streams. We must therefore start the design at the pinch, finding matches that fulfil this condition. DESIGN ABOVE THE PINCH. In this example, above the pinch there are two hot streams at pinch temperature, therefore requiring two pinch matches. In Figure 1.15 a match between streams 2 and 1 is shown, with a T/H plot of the match shown in inset. (Note that the stream directions have been reversed so as to mirror the directions in the grid representation).
CP (kW/oC) 2 4 1 3 3.0 1.5 2.0 4.0 TMIN
H Infeasible !!
QH,MIN = 20 kW
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In Figure 1.16, streams 2 and 3 are matched, and now the relative gradients of the T/ H plots mean that putting load on the exchanger opens up the T.
CP (kW/oC) 2 4 1 3 3.0 T 1.5 2.0 4.0 TMIN TMIN
QH,MIN = 20 kW
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In the example problem, since stream 2 above the pinch requires 240 kW of cooling and stream 3 above the pinch requires 240 kW of heating, co-incidentally the 2/3 match is capable of satisfying both streams. However, the 4/1 match can only satisfy stream 4, having a load of 90 kW and therefore heating up stream 1 only as far as 125 oC. Since, both hot streams have now have been completely exhausted by these two design steps, stream 1 must be heated from 125 oC to its target temperature of 135 oC by external hot utility as shown in Figure 1. 17.
2 4
170
oC
90
oC
150 oC 125 oC 90 kW
90 oC 80 oC 80 oC 240 kW
135 oC
H 140 oC 20 kW
1 3
2.0 4.0
Fig. 1.17 Example problem hot end design. Maximizing exchanger loads.
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T TMIN
2 4
Infeasible!!, Why?
1 2.0
Feasible
Fig. 1.18 Example problem cold design. 2/1 Match acceptable, 2/4 match infeasible. Immediately below the pinch, the necessary criterion is: CPHOT CPCOLD . which is 50 inverse of the criterion for design immediately above the pinch.
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30 oC
1.5
90 oC 35 oC
70 oC
80 oC
35 oC
20 oC
1 2.0
1 20 oC Feasible
T > TMIN H
90 kW
30 kW
Fig. 1.19 Example problem cold end design. Putting a load of 30 kW on this march leaves residual cooling of 60 kW on stream 4 which must be taken up by cold utility. This is as predicted by the Problem 51 Table analysis.
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2 4
170 oC 150 oC
1 2
90 oC 90 oC
3 4 70 oC C 60 kW
135 oC
125 oC 90 kW
80 oC
35 oC 90 kW 30 kW
20 oC
1 3
2.0
20 kW 140 oC 240 kW
80 oC
4.0
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Summarizing:
Dividing the problem at the pinch, and designing each part separately. Starting the design at the pinch and moving away. Immediately adjacent to the pinch, obeying the constraints: CPHOT CPCOLD (Above). CPHOT CPCOLD (Below).
Maximizing exchanger loads. Supplying external heating only above the pinch, and external cooling only below the pinch.
These are the basic elements oh the Pinch Design Method of Linnhoff and Hindmarsh (1982).
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1 Identification of hot, cold and utility streams in the process. 2 Thermal data Extraction for process and utility streams
5 Estimation of minimum energy cost targets 6 Estimation of HEN capital cost targets 7 Estimation of optimum TMIN value
3 Selection of initial TMIN value 4 Construction of Composite and Grand Composite curves
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TIER I: FUNDAMENTALS
1. HEAT RECOVERY NETWORKS (HEN). 2. STEADY STATE SIMULATION of HENs. 3. OPERABILITY ANALYSIS of HENs. 4. RETROFIT of HENs. 5. MASSS EXCHANGE NETWORKS (MEN). 6. OPERABILITY ANALYSIS of MENs.
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HENs.
2.1 Introduction 2.2 Response equations. 2.3 Modeling the thermal performance of HENs.
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2.1 Introduction.
Flexible Network:
For an existing heat recovery network to maintain its target temperatures when changed operating conditions come into being is very significant to avoid bottlenecks at individual heat exchangers. Typical de-bottlenecking practices for heat exchangers include modifications to surface area (overdesign) and to heat transfer coefficients (use of bypass). If the modified operating conditions return to their original condition after a network has been de-bottlenecked, new disturbances are produced and the network has to be de-bottlenecked again in order to achieve the specified target temperatures. A Flexible Network is one that is capable to providing an acceptable performance after being subjected to those two de-bottlenecking stages.
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Flow rate
time
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Fig. 2.2 propagation of disturbances through networks. The effect of the disturbances on target temperatures can be assessed by determining the steady state response of the network. This steady state response can be used to implement retrofit strategies that will lead to flexible systems able to cater for seasonal or temporary variations in operating conditions
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T3
T4
Cold
T1 T
T2 T3
T4
T1 T2 = T1 T3
(2.1)
H Fig. 2.3 Temperature profiles of a heat Exchanger Where the hot stream is the CPmin stream.
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NTU =
UA CPmin
(2.2)
where U is the overall heat transfer coefficient, and A is the exchanger surface area.
) (
1/ 2
(2.3)
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BP = ByPass
T2 T3
T3 T4
M T2
(b)
T1 r1.2 T5
Fig. 2.4 Exchanger variables in steady sate simulation: (a) single heat exchanger and (b) single heat exchanger with bypass.
Variables Entry Temperatures Output Temperatures T1, T3 T2, T4 Entry Temperatures Output Temperatures Flow rate fraction (rn,j) of each branch of the divided stream
Variables
T1, T4 T2, T3 (from Mixing Point, M), T5 r1.1, r1.2 (The number of outputs that a split generates [j] corresponds to the number of branches specified). Here n =1, j = 2
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NV = S + 2 E + M + 2 BP
where S the number of process streams. For the exchanger in Fig. 2.4b
(2.4)
NV = 2 + 2(1) + 1 + 2(1) = 7
Total number of equations in a network.
For a system to be fully defined, the number of variables must be equal to the number of equations. In the case of an existing heat exchanger network, the equations that can be written are:
a) The thermal effectiveness equation and the heat balance equation for every heat
exchanger.
From the thermal effectiveness equation Eq. (2.1), the outlet temperature of the CPmin stream in the case of Fig. 3.3b can be expressed as
T2 = T1 (T1 T4 )
(2.5)
Combining Eq. (2.5) with the heat balance equation about the exchanger, the outlet temperature of the CPmax stream can be expressed as (2.6)
T5 = T4 + C (T1 T4 )
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& m
1
n, j
& n ,Total =m
(2.7)
r1.1 T3 M T2 r1.2
BP T1 T5
rn, j = 1
1
(2.8)
rn , j
T4
(2.9)
Fig. 2.4b
H 3 = H 2 + H1
& Cp (T Tref ) H =m
(2.10)
Where H is the stream enthalpy content. For a given reference state (Tref.) the enthalpy content can be expressed as
(2.11)
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(2.12)
Applying Eq. (2.11) to the various streams at the mixing point, and combining with Eqs. (2.10) and (2.12) and rearranging gives
(2.13)
d. e.
The stream supply temperatures which are known. The j-1 flow fractions at every split point that are known.
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T1 T4 H
T2 = (1 )T1 + T3
and the second equations required come from heat balance about exchanger and it can written as
T3
T2
T2
E T1
Hot
T3
T4
T4 = CT1 + (1 C )T3
Cold
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The solution of system equations for a single exchanger can be expressed into matrix form as follow AT = B where: T vector represents exchanger outlet and inlet temperatures A represents outlet and inlet temperatures relation of exchanger B represents temperatures known values. In this case, T1 = 1 and T3 = 3. The matrix equation can be written in developed form as
0 0 0 T1 1 1 (1 ) 1 T 0 0 2 = 0 0 1 0 T3 2 C C 0 ( 1 ) 1 T4 0
The production of a simulator for heat recovery network required of equations generation considering each one exchanger and, if there is, to mixing point existing.
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T1
1
T5 T8
T4
T3
T10 T11
T12
T13
15 EQUATIONS ARE REQUIRED TO SOLVE THE SYSTEM. The simultaneous solution of this system of equations permits the calculation of all network 68 temperatures.
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