What about Retrofit Design of

Heat Exchanger Networks ?

Process, Energy and System

Optimal Retrofit Optimal Grassroot

Optimal Reuse of installed Heat Exchangers
Requires accurate Modeling (Rating)
Shorter Paybacks (especially Energy Projects)

Phases are the same, but Content is different

Data Extraction has been discussed already
Targeting with focus on Optimal Value for Tmin
Process Modifications more difficult than in Grassroot
Network Design is focused on reduced Heat Transfer
across the Pinch point (Process and Utility Pinches)
Optimization is used to maximize the Utilization of
Existing Heat Exchangers through Loops and Paths

Heat Integration Retrofit Design

T. Gundersen

Retro 1

Penalty Heat Flow Diagram

T
Process, Energy and System

ST

Hot Streams

Cold Streams

QPC

Pinch
Hot Streams

CW

QP = QPP + QPH + QPC

QPP

QPH

Cold Streams

Q: What Pinch ? Which Tmin ?

Heat Integration Retrofit Design

T. Gundersen

Retro 2

Energy Target Plot

Process, Energy and System

QH,min
QH,exist

E
QH,new

b
c

HRAT
HRATnew

HRATexist

HRAT = Heat Recovery Approach Temperature

Heat Integration Retrofit Design
T. Gundersen

Retro 3

Savings vs. Investments

Process, Energy and System

Savings
(US$/yr)

PB=3
PB=2
PB=1

Investment
(US$)
Invmax

min HRAT subject to Inv Invmax and PB PBmax

Heat Integration Retrofit Design
T. Gundersen

Retro 4

Examples of Cross-Pinch Heat Transfer

TP,H

Process, Energy and System

TH,in

TH,out

mCpH
C
mCpC
H

TC,out

TC,in
TP,C

QXP = mCpH TH ,in TP, H mCpC TC ,out

>
TP,C = 0
<

Heat Integration Retrofit Design

T. Gundersen

Retro 5

Shifting in Retrofit Design

QC QXP

Process, Energy and System

C
QC

HP

QXP

LP

HP

LP

QXP

QH QXP

QH

C
QC

H
QH

Heat Integration Retrofit Design

T. Gundersen

Retro 6

Example of an Existing Network

Pinch
180

Process, Energy and System

270

H1

214.4

mCp
(kW/C)
160

Ca

18.0
980 kW

220
H2

120

60
22.0

Cb
1320 kW

210

50

160

20.0

2200 kW
160

1000 kW
210

C1

C2

50.0

2500 kW
160

QPP = 22 (220 - 180) = 880 kW

QPC = 18 (214.4 - 180) = 620 kW
QPH =
0 kW

QP = 1500 kW = 2500 - 1000

Heat Integration Retrofit Design

T. Gundersen

Retro 7

Changing Operating Conditions (shifting)

Process, Energy and System

Pinch
180
270
H1

mCp
(kW/C)

180

214.4
620 kW

180

880 kW
210
1
1000 kW
210

18.0

360 kW

220
H2

160
Ca

80

60

22.0

50

20.0

Cb

440 kW
160

2
2200 kW
160

C1
50.0

C2

2500 kW
160

Releases Heat above the Pinch by changing Operating

Conditions (Temperatures) for Exchanger 2 and Cooler Ca
Heat Integration Retrofit Design
T. Gundersen

Retro 8

Network After Modifications (Retrofit)

Process, Energy and System

Pinch
180

270
H1

214.4

mCp
(kW/C)

160

180

Ca

18.0

360 kW

220
H2

180

80

60
Cb

22.0

440 kW
210

160

1
1000 kW
210
H

190

1000 kW

620 kW
4
880 kW

50
2

C1

20.0

2200 kW
160
C2

50.0

160

The Project requires Purchase of 2 new Units and

additional Area (new shell ?) to Unit 2 (smaller T )
Heat Integration Retrofit Design
T. Gundersen

Retro 9

A simpler Retrofit Solution

Process, Energy and System

Pinch
180
270
H1

214.4

mCp
(kW/C)
180

160

Ca

18.0

360 kW
220
H2

120

Cb

60

22.0

1320 kW
210

160

1
1000 kW

210

H
1880 kW

172.4

2
160
C2

50
C1

20.0

2200 kW
50.0

620 kW
160

The Project requires Purchase of only 1 new Unit,

while the Energy Savings is 620 kW (versus 1500)
Heat Integration Retrofit Design
T. Gundersen

Retro 10

WS-7: A simple Retrofit Problem

Process, Energy and System

250C

H1

170C

50C

mCp
(kW/C)
100

C
12000 kW

220C
I
8000 kW

120C

70C
H

C1

80

Given:
Tmin = 5C
U = 1.0 kW/(m2K)
CST = 0.1 NOK/kWh
CCW = 0 NOK/kWh

4000 kW

Further:
Steam available at 250C, Cooling Water at 20C (constant)
8000 Operating Hours per Year
Cost of new Exchanger: Chex = 0.5 + 0.01A (m2 and MNOK)
Cost of moving/repiping existing Exchanger: Chex = 0.5 MNOK
Maximum Payback: PBmax = 3 years
Heat Integration Retrofit Design
T. Gundersen

Retro 11

Targeting by using Pro_Pi Software

Demand Curves
10000

Q (kW)

Process, Energy and System

12000

8000
6000
4000
2000
0

10

20

30

40

50

60

Global temperature difference (K)

Result: For Tmin 30C: QH,min = 0 kW, QC,min = 8000 kW
Heat Integration Retrofit Design
T. Gundersen

Retro 12

WS-7 (cont.): Alternative Retrofit Projects

250C

H1

50C

170C

mCp
(kW/C)

250C

100

H1

139.23C
I

Process, Energy and System

C1

922.9 kW

11077.1 kW

80

4000 kW

70C

208.46C

220C

C1

8000 kW

80

Existing Design: PB = n.a.

Project # 1: PB = 0.20 yr = 2.4 months

I = 0 MNOK, E = 0 MNOK/yr

I = 0.5 MNOK, E = 2.46 MNOK/yr

250C

H1

8922.9 kW

70C

120C

100

12000 kW

220C

50C

mCp
(kW/C)

170C

II

130C

50C
C

mCp
(kW/C)

250C

100

H1

130C

170C
I

II

120C

8000 kW

70C
II

100

C
8000 kW

8000 kW
220C

50C

mCp
(kW/C)

C1

80

I
8000 kW

4000 kW

70C

120C

220C

II

C1

80

4000 kW

Project # 2: PB = 0.38 yr = 4.6 months

Project # 3: PB = 0.46 yr = 5.5 months

I = 1.23 MNOK, E = 3.2 MNOK/yr

I = 1.47 MNOK, E = 3.2 MNOK/yr

Heat Integration Retrofit Design

T. Gundersen

Retro 13

WS-7 (cont.): Alternative Retrofit Projects

Savings

PB = 4.6 months

MNOK/yr

Process, Energy and System

3.0

The Optimum
PB = 2.4 months

2.0

PB = 11.8 months

1.0

Investment

0
0

0.5

1.0

1.5

MNOK

Heat Integration Retrofit Design

T. Gundersen

Retro 14

Stream

Process, Energy and System

H1
H2
C1
C2

Ts
C

Tt
C

mCp
kW/C

H
kW

250
200
130
140

120
180
290
240

40
80
50
20

5200
1600
8000
2000

Steam
Cooling Water

WS-10:
Retrofit
Optimization
with Loops
and Paths

320C (condensing)
20C 30C

Tmin = 10C
QH,min = 4000 kW
QC,min = 800 kW

Grand Composite Curve

T (C)
350
300
250

TPinch = 200C/190C and 140C/130C

200
150

Q (kW)

100
0

500

1000

1500

2000

2500

3000

3500

4000

4500

Heat Integration Retrofit Design

T. Gundersen

Retro 15

WS-10: Existing Network

Process, Energy and System

250

200

II

200

H1

mCp (kW/C)

140
165

120

[40]

Q=1800

III

200

180
[80]

H2
290
Ha
Q=5000

130

158

190

Q=1600

240

C1

Q=1400
140
C2

Q=2000
190

Targeting for Tmin = 10C:

QH,min = 4000 kW , QC,min = 800 kW

[50]

[20]
130

Cross Pinch Heat Transfer:

QXP,I = 1000 kW , QXP,C = 1000 kW

Heat Integration Retrofit Design

T. Gundersen

Retro 16

WS-10: Retrofit Network

mCp (kW/C)

Process, Energy and System

IV

250
H1

200

200

II

175

120

140

C
Q=800
[1800]

III

[40]
180
[80]

H2
290
Ha

230

Q=3000 Q=2000
[5000] UA=138.6
240
190
Hb
Q=1000
UA=9.7

130

158

190
Q=1600

C1

Q=1400 [1400]
UA=106.1 [36.5]

[50]

140
C2

[20]

Q=1000 [2000]
UA=50.1 [71.7]

Investments: New Exchangers IV and Hb

and Additional Area for Existing Exch. II

Savings: 1000 kW Reduction

in Steam and Cooling Water

Heat Integration Retrofit Design

T. Gundersen

Retro 17

WS-10: Summary

a) Unchanged Energy Consumption

Loop A: Ha (+x) IV (-x) I (+x) Hb (-x) b) Better Use of Existing Ha and I
c) Reduces the Area for new Hb and IV

Process, Energy and System

Loop B: IV (+y) II (-y)

a) Unchanged Energy Consumption

b) Better Use of Existing I
c) Area increase in IV > Area saved in II

Path C:

a) Increased Energy Consumption

b) Reduces Area for Exchangers IV & II
c) Less (!!) Use of Existing I

Ha (+z) IV (-z) C (+z)

Path D: Ha (+w) II (-w) C (+w)

(This path is dependent Combine B and C)
Path E:

Hb (-v) I (+v) C (-v)

a) Increased Energy Consumption

b) Reduces Area for Exchangers II & IV
c) Less (!!) Use of Existing III
a) Reduced (!!) Energy Consumption
b) Better Use of Existing I
c) Increased Additional Area for II

Loop A most promising, possibly combined with

Path C if Existing Exchanger I becomes limiting

Optimization
with 4 DOFs

Heat Integration Retrofit Design

T. Gundersen

Retro 18

Heat Recovery and Iterative Design

Process, Energy and System

R
R

U
S

R
S
H
U

=
=
=
=

Reactor System
Separation System
Heat Integration
Utility System

Decomposition

H
U

Interactions

Process Modifications
T. Gundersen

Proc. Mods. 1

Process Modifications
T
Process, Energy and System

QH,min

QC,min

The Plus / Minus - Principle

Process Modifications
T. Gundersen

Proc. Mods. 2