Process Integration

CHEN20082 Process Integration 10 Semester 2 Undergraduate Level 2 Salman Shahid Unit coordinator Simon Perry Unit coordinator 1 FHEQ level (Framework for Higher Education Qualifications) ' Middle part of Bachelors ' European Credit Transfer & Accumulation System Rating : 5.0 The use of energy to produce products is fundamental in the chemical process industries. Energy sources such as gas, oil, and coal are becoming increasingly costly, and also lead to environmental problems. Minimising the use of external heating and cooling sources and making the most efficient use of available energy is a cornerstone in the design of chemical processes.<div><div><div>This unit will briefly examine the various types of heat exchanger devices available to transfer heat between streams in chemical processes, and evaluate factors that contribute to the overall specification and design of these heat exchange devices, including heat transfer coefficients, pressure drops, and temperature differences.The unit will also evaluate opportunities to minimise and target energy use prior to the detailed design of the energy exchange (or heat exchanger) network. Such targets can be used to scope and screen many design options quickly and effectively without having to carry out the designs. Methodologies, including the well established Pinch Analysis, are developed and evaluated for both new design and retrofit (existing design) scenarios. Once design options have been chosen using targets (both energy and capital), then systematic procedures allow the targets to be achieved in practice. The external heating and cooling requirements of the chemical process can also be evaluated and included in this design. The use and design of fired heaters in providing external heating to chemical processes will be considered in some detail.</div></div></div> The use of energy to produce products is fundamental in the chemical process industries. Energy sources such as gas, oil, and coal are becoming increasingly costly, and also lead to environmental problems. Minimising the use of external heating and cooling sources and making the most efficient use of available energy is a cornerstone in the design of chemical processes.This unit will briefly examine the various types of heat exchanger devices available to transfer heat between streams in chemical processes, and evaluate factors that contribute to the overall specification and design of these heat exchange devices, including heat transfer coefficients, pressure drops, and temperature differences.The unit will also evaluate opportunities to minimise and target energy use prior to the detailed design of the energy exchange (or heat exchanger) network. Such targets can be used to scope and screen many design options quickly and effectively without having to carry out the designs. Methodologies, including the well established Pinch Analysis, are developed and evaluated for both new design and retrofit (existing design) scenarios. Once design options have been chosen using targets (both energy and capital), then systematic procedures allow the targets to be achieved in practice. The external heating and cooling requirements of the chemical process can also be evaluated and included in this design. The use and design of fired heaters in providing external heating to chemical processes will be considered in some detail.Contents Introduction (Heating and Cooling requirements in chemical processes; hot and cold stream identification; overall chemical process design and heating and cooling)Process Integration: The Basic Terminology (Onion diagram; hot and cold stream definitions; heat duties of streams; minimum temperature differences (ΔTmin ); violations in temperature differences)Setting Energy Targets and the Problem Table Algorithm (Simple energy balances; accounting for ΔTmin; heat recovery and composite curves; ΔTmin  selection impact; Problem Table algorithm; Problem Table methodology)The Heat Recovery Pinch (Process Pinch significance; heat sources and heat sinks; heat transfer across the pinch; implications of cross pinch heat transfer)Heat Exchanger Network Representation (Conventional HEN representation; Grid Diagram form of HEN representation; representation of cross-pinch heat transfer)Heat Exchanger Network Design for Maximum Heat Recovery (Targeting information in HEN design; identification of feasible heat transfer above the pinch; identification of feasible heat transfer below the pinch; heat recovery matching rules and identification of all feasible heat recovery matches; determination of heat recovery amounts per heat exchanger match; complete HEN design for a chemical process and targeting comparisons)Stream Splitting (Identification of heat recovery problems above the pinch; identification of heat recovery problems below the pinch; modification of pinch design rules; flowrates in split designs and degrees of freedom; examples of HEN design with split streams)Multiple Utilities and HEN Design (Sources of hot and cold utilities; relationship between Problem Table and Grand Composite curve; representation and features of the Grand Composite curve; simple modelling of hot and cold utilities; meeting Grand Composite curve/chemical process requirements from different sources of hot and cold utilities; integrating hot and cold utilities in Heat Exchanger networks; example of HEN design with multiple utilities)Threshold Problems (Definition of threshold chemical processes; differences between pinched problems and threshold problems; design of Heat Exchanger networks for threshold problems; Examples of threshold chemical processes; threshold problem HEN design example)Capital Energy Trade-Offs (energy cost, capital cost, and total cost relationships; area targeting; balanced composite curves; heat exchanger unit targets; optimisation of heat exchanger networks with loops and paths)Fired Heater Design (configuration of fired heaters; simple models of fired heaters; fuel combustion in fired heaters; flame temperatures; heat transfer in fired heaters (radiant, shield, convective); fired heater example calculations)Conclusions (chemical process energy targeting; HEN design and targeting; significance of heating and cooling requirements for chemical processes; significance of pressure drop in Heat Exchanger networks; the use and modelling of fired heaters in chemical processes). <div><div>The unit aims to:Examine, understand, and evaluate the use of heat exchangers, including networks of heat exchangers, within chemical processes in order to maximise heat recovery, and with regards to operating and capital costs. The unit will evaluate techniques to determine the effective use of energy within chemical processes, maximising heat recovery and minimising the use of external heating and cooling utilities. Techniques will be developed for the design of networks of heat exchangers within chemical processes that meet targeted minimum energy requirements. Additional heating and cooling requirements of chemical processes will be evaluated, and suitable types of hot and cold utilities required to meet this requirement will be appraised. Methods of integrating hot and cold utilities into chemical processes will be assessed. Capital costs of heat recovery will be examined with the use of area targeting approaches. Detailed design of fired heaters will be examined.</div></div> ILO 1: Assess the sources and sinks of energy contained in chemical processes and the significance of effective integration to achieve energy efficiencyILO 2: Develop, evaluate, and demonstrate the targeting methodologies available to heat integrate chemical processes in order to maximise heat recovery, minimise externally sourced energy use, and improve energy efficiencyILO 3: Appraise and assess the implications of the process pinch on heat recovery and external energy use,  and the heat integration potential on the design of heat exchanger networksILO 4: Develop, evaluate, and demonstrate methods of heat exchanger network design in order to achieve maximum targeted heat recovery and minimum externally sourced  energy use in chemical processesILO 5: Evaluate the sources of heating and cooling supply utilities, and demonstrate and assess methods of heating and cooling supply utilities integration into chemical processes and heat exchanger networksILO 6: Examine and evaluate capital cost implications of heat recovery by area targeting techniquesILO 7: Assess and demonstrate models of fired heater designs for the production of high temperature heat sources for chemical processes <div>Lectures provide fundamental aspects supporting the critical learning of the module and will be delivered as pre-recorded asynchronous short videos via our virtual learning environment.Synchronous sessions will support the lecture material with Q&A and problem-solving sessions where you can apply the new concepts. Surgery hours are also available for drop-in support.Students are expected to expand the concepts presented in the session and online by additional reading (suggested in the Online Reading List) in order to consolidate their learning process and further stimulate their interest to the module.Study budget:<ul> <li>Core Learning Material (e.g. recorded lectures, problem solving sessions): 24 hours</li> <li>Self-Guided Work (e.g. continuous assessment, extra problems, reading): 44 hours</li> <li>Exam Style Assessment Revision and Preparation: 32 hours</li></ul></div> 0 Other 100% <table class="Table" style="border-collapse:collapse; border:solid windowtext 1.0pt" width="0"> <tbody> <tr> <td style="border:solid windowtext 1.0pt; width:276.2pt; padding:0cm 5.4pt 0cm 5.4pt" valign="top" width="368">Assessment Types</td> <td style="border:solid windowtext 1.0pt; width:184.25pt; border-left:none; padding:0cm 5.4pt 0cm 5.4pt" valign="top" width="246">Total Weighting</td> </tr> <tr> <td style="border:solid windowtext 1.0pt; width:276.2pt; border-top:none; padding:0cm 5.4pt 0cm 5.4pt" valign="top" width="368">Continuous assessment</td> <td style="border-bottom:solid windowtext 1.0pt; width:184.25pt; border-top:none; border-left:none; border-right:solid windowtext 1.0pt; padding:0cm 5.4pt 0cm 5.4pt" valign="top" width="246">30%</td> </tr> <tr> <td style="border:solid windowtext 1.0pt; width:276.2pt; border-top:none; padding:0cm 5.4pt 0cm 5.4pt" valign="top" width="368">Exam style assessments</td> <td style="border-bottom:solid windowtext 1.0pt; width:184.25pt; border-top:none; border-left:none; border-right:solid windowtext 1.0pt; padding:0cm 5.4pt 0cm 5.4pt" valign="top" width="246">70%</td> </tr> </tbody></table>Please note that the exam style assessments weighting may be split over midterm and end of semester exams. Feedback on problems and examples, feedback on coursework and exams, and model answers will also be provided through the virtual learning environment. A discussion board provides an opportunity to discuss topics related to the material presented in the module. BEng(Hons) Chem Eng w IE BEng(Hons) Chemical Engineerin Second Year Mandatory BEng(Hons) Chem Eng BEng(Hons) Chemical Engineerin Second Year Mandatory MEng (Hons) Chem Eng MEng Chemical Engineering Second Year Mandatory MEng (Hons) Chem Eng w I E MEng (Hons) Chem Eng w I E Second Year Mandatory MEng (Hons) Chem Eng w SIE MEng Chem Eng w SIE Second Year Mandatory MEng (Hons) Chem Eng w Bio MEng Chem Eng with Biotech Second Year Mandatory MEng (Hons) Chem Eng w Chem MEng (Hons) Chem Eng w Chem Second Year Mandatory MEng (Hons) Chem w Env. Tech MEng Chem Eng w Env. Tech Second Year Mandatory MEng (Hons) Chem Eng w BM MEng Chem Eng w BM Second Year Mandatory MEng Chem Eng w Energy & Env MEng Chem Eng with Energy Second Year Mandatory N Reading lists are accessible through the Blackboard system linked to the library catalogue. Lectures 24 0 76