Conceptual Process Design Suite: Tutorials

Conceptual Process
Design Suite
Tutorials
Notices and Trademarks
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Table of Contents
1 Crude Pre-Heat Train Network.............................. 1-1
1.1 Introduction .................................................... 1-2
1.2 Entering Process Information ............................. 1-4
1.3 Examining the Targets .................................... 1-12
1.4 Building the Heat Exchanger Network................ 1-15
1.5 References .................................................... 1-33
2 Data Extraction from UniSim Design..................... 2-1

2.1 Introduction .................................................... 2-2
2.2 Preparing for Data Extraction ............................. 2-5
2.3 Editing the UniSim Design Case.......................... 2-8
2.4 Performing the Data Extraction ........................ 2-17
2.5 Adjusting the Extracted Data in ExchangerNet.... 2-30
3 Automatic HEN Design in HI Project ..................... 3-1

3.1 Introduction .................................................... 3-2
3.2 Creating a HI Project for Automatic Design Generation
3-7
3.3 Generating HEN Designs ................................. 3-13
3.4 References .................................................... 3-16
4 Heat Exchanger Network Retrofit ......................... 4-1

4.1 Introduction .................................................... 4-2
4.2 Creating an HI Project for Retrofit ...................... 4-3
4.3 Performing the Retrofit ................................... 4-18
4.4 Comparing Designs ........................................ 4-25
iii
iv
Crude Pre-Heat Train Network 1-1
1 Crude Pre-Heat Train

Network
1.1 Introduction .................................................................................. 2
1.2 Entering Process Information ........................................................ 4

1.2.1 Setting Unit Preferences ........................................................... 4
1.2.2 Creating an HI Case ................................................................. 5
1.2.3 Entering Process Stream Data.................................................... 6
1.2.4 Entering Utility Stream Data .....................................................10
1.3 Examining the Targets ..................................................................12

1.3.1 Range Targeting......................................................................13
1.4 Building the Heat Exchanger Network ..........................................15

1.4.1 Accessing the HEN Design View ................................................15
1.4.2 Modifying HEN Diagram Properties ............................................16
1.4.3 Adding a Splitter .....................................................................17
1.4.4 Adding Heat Exchangers ..........................................................18
1.4.5 Using the Worksheet to Enter Heat Exchanger Information ...........26
1.4.6 Completing the Pre-Flash Section ..............................................28
1.4.7 Completing the Heat Exchanger Network....................................31
1.5 References....................................................................................33
1-1
1-2 Introduction
1.1 Introduction
In this tutorial, you will design a heat exchanger network for a crude
pre-heat train. A network will be created based on a process flow
diagram proposed by a contractor. The concepts introduced here are
used throughout the tutorial:
• creating process and utility streams,
• adding heat exchangers, and
• using the worksheet to manipulate the network.
Crude oil is often fractionated to produce saleable products such as

heavy and light naphtha, kerosene, gas, and fuel oils. The proposed
flowsheet was adapted from B. Linnhoff, D.W. Townsend, et al1 and
appears in Figure 1.1. The crude oil is split and heated in two heat
exchangers, 10 and 6, by the Fuel Oil and Light Naphtha product
streams, respectively. The crude feed is then mixed back together and
passed through the desalter unit.
Effluent leaving the desalter is heated up further in heat exchangers 9,

7, 8, 5, and 4 by the product streams Heavy Naphtha, Kerosene,
Reflux, Gas Oil, and Fuel Oil, respectively. An air cooler, coolers using
cooling water, and boiler feed water heaters are used to further cool the
product streams down to their target temperatures.
After the crude oil has been heated by the products, it is passed
through a Pre-Flash operation to remove the Light naphtha cut. The
heavier components from the Pre-Flash operation are heated by the
hottest portion of the fuel oil in heat exchanger 3, and then passed
through two furnaces. The crude tower takes the heated feed, and
separates the Light Naphtha and the Fuel Oil cuts. The remaining cuts
pass to the second column, the stripper. The stripper column also
produces three other products: Gas Oil, Heavy Naphtha, and Kerosene.
1-2
Figure 1.1: Process Flowsheet
1-3
1-4 Entering Process Information
1.2 Entering Process

Information
In order to analyze and create the heat exchanger network described
earlier, all of the information from the pre-heat train must be entered
into ExchangerNet. This includes all process stream information and
utility stream information.
1.2.1 Setting Unit Preferences

Before you begin, verify that the units currently selected in the
preferences are the ones you want to use. For this example, the desired
unit for energy is MW.
1. On the Tools menu, click Preferences. The Session Preferences
view appears.
2. Click on the Variables tab, and select the Units page.
3. Select EuroSI from the Available Unit Sets list, and click the Clone
button. You have created a custom unit set.
Figure 1.2
4. In the Unit Set Name field, change the name of the custom unit
set to Energy Integration-Euro SI.
5. In the Display Units group, scroll through the table until you find
Energy. The current energy flow unit is set to kcal/h.
1-4
6. Click the Unit dropdown list for Energy Flow and Select MW.
Figure 1.3
7. Click the Close icon to close the Session Preferences view.
1.2.2 Creating an HI Case

Close icon
Now, you can create the Heat Integration (HI) Case.
To access the main HI Case view, do one of the following.

• From the Features menu, select HI Case.
• From the Managers menu, select Heat Integration Manager.
The Heat Integration Manager view appears. In the left column,
select HI Case, then click the Add button.
• On the tool bar, click the Heat Integration Manager icon. The
Heat Integration Manager view appears. In the left column,
select HI Case, then click the Add button.
Heat Integration Manager
icon When the HI Case view appears you should see the Process Streams
tab as shown in the figure below.
Figure 1.4
1-5
1.2.3 Entering Process Stream

Data
You will now begin entering the stream information, starting with the
Fuel Oil stream.
1. Click in the Name column.
2. Type in the name Fuel Oil, then press the ENTER key. The cursor
automatically moves to the Inlet T cell.
3. This stream exits from the bottom of the crude tower at a
temperature of 349°C.
Ensure that the Inlet T cell is active, and type 349.
The default unit that appears in the unit drop-down list is already
degrees Celsius, so it does not need to be changed.
4. The desired outlet of this stream is 194°F. The default units are in
degrees Celsius.
Ensure that the Outlet T cell is active and type 194.
To change the units, do one of the following:
• Click on the drop-down list that appears and select F.
OR
• Press the SPACE BAR and type F, then press ENTER. ExchangerNet
automatically converts the value to the default units.
Figure 1.5
The temperature value in Once the inlet and outlet temperatures are entered, ExchangerNet
the Outlet T cell
determines the stream type as hot or cold. The stream type is indicated
automatically changes
from 194°F to 90°C, in the second column by a red arrow for hot streams or a blue arrow for
because degrees Celsius is cold streams.
the default unit.
1-6
Segmenting Process Streams

To complete this stream’s information, the enthalpy or flow heat
capacity must be entered. All other information is optional.
For this example, the Fuel Oil stream must be segmented. Stream
segmentation is extremely useful for streams that change phase or
have non-linear variations in enthalpy as the temperature changes.
Double-clicking in the HTC 1. Double-click in any cell of the Fuel Oil row (except for the HTC
column opens the HTC column) to open the Process Stream view.
Default Values view, which
displays a list of default
heat transfer coefficients Figure 1.6
for various materials.
2. To add a segment, click in the target outlet temperature cell (90°C)

and click the Insert Segment button.
A blank row appears above the target outlet temperature.
3. The outlet temperature of the first segment is 243°C.
Click in the empty Outlet T cell and type 243.
4. The enthalpy for this section is 22.8 MW.
Click in the Heat Load cell and type 22.8.
Always click the target 5. Repeat steps #2, #3, and #4 to add more segments with the
Outlet T cell before
clicking the Insert following information:
Segment button. If you
insert the segment values Segment Outlet T
in the wrong order, a Heat Load (MW)
(°C)
warning appears.
213 5.9
167 8.2
90 12.9
1-7
6. After entering the information for the last segment (167°C to 90°C),
the process stream is complete as should appear as shown in the
figure below.
Figure 1.7
7. To view the temperature versus enthalpy plot, click on the Graphs

tab. The plot appears similar to the figure below.
Figure 1.8
8. Click the Close icon to return to the Process Streams tab of the HI
Case view.
Close icon The red arrow beside the stream name indicates it is a hot stream.
1-8
Now that you know how to successfully enter process stream

information and create segmented streams, enter the following stream
information.
Enter the stream name, first Inlet T value and the target
(last) Outlet T value on the Process Streams tab before
accessing the Process Stream view to enter the segment
information.
Enter only the Outlet T values and the Heat Load/Enthalpy
values; the Inlet T values are calculated for you.
If you try to enter the segment values in the wrong order, a
warning appears.
Stream Heat Load/Enthalpy

Inlet T (°C) Outlet T (°C)
Name (MW)
Gas Oil 341 210 13.8
210 172 3.6
172 111 5.3
111 65 3.5
Kerosene 268 135 8.7
135 38 5.2
Reflux 251 169 8.6
169 77 8.4
Heavy 235 127 0.8
Naphtha
127 38 0.6
Light 168 136 19.2
Naphtha 136 118 8.6
118 108 4.1
108 71 11.2
Desalter 15.6 121 39.9
Feed
Pre-Flash 120 122 0.8
Feed
122 163 17.3
163 186 13.8
186 194 5.8
Crude Tower 189 237 22.9
Feed 237 265 13.9
265 368 68
1-9
9. After entering all the information in the above table, the Process
Streams tab in the HI Case view appears similar to the figure
below.
Figure 1.9
1.2.4 Entering Utility Stream Data

Now that all of the process stream information has been specified, the
utilities to be used for heating and cooling must be specified.
1. On the HI Case view, click on the Utility Streams tab.
The utilities for this example will be selected from the list of default
utilities included with ExchangerNet.
2. In the Name column, move the cursor over the <empty> cell to
activate the down arrow .
Figure 1.10
The Hot and Cold status bars appear below the tab when the Utility Streams tab is
selected. The status bars indicate that there are not enough hot and cold utilities to
satisfy the process streams.
3. Click the down arrow to open the drop-down list.
1-10
4. Scroll through the list until you find Cooling Water, then select it.
Figure 1.11
The Cold status bar indicates that cold utilities are now sufficient. This means
that the cold utility entered can be used to cool all of the hot process
streams.
5. Repeat steps #2 - #4 to add the following utilities:

• LP Steam Generation
• Air
• Fired Heat (1000)
The Utility Streams tab should now appear similar to the figure below.
Figure 1.12
The Hot status bar now displays a sufficient status.
All utilities have default costs associated with them. This

cost information is required to calculate the operating cost
targets for the system.
1-11
1-12 Examining the Targets
6. Click the Economics tab.
Figure 1.13
A default set of economic parameters is supplied by

ExchangerNet.
Since at least one set of economic data must be available for the
calculation of the capital cost targets and network capital costs, this
information is left as is.
1.3 Examining the Targets

Now that all of the data required to create the crude pre-heat train
network has been entered, you can examine the various engineering
targets calculated by ExchangerNet. These targets represent the
performance of an ideal heat exchanger network.
To open the Targets view:

1. On the HI Case view, click on the Open Targets View icon that
appears at the bottom of the view for all tabs.
2. The Targets view appears.
Open Targets View icon
Figure 1.14
1-12
The minimum number of units required to build this heat exchanger

network is 11. The network you will build is based on Figure 1.1:
Process Flowsheet, which has 19 exchangers (including heaters and
coolers). Therefore, the network that will be built will be over the unit
targets. The network, however, may require less energy from the utility
streams than the targets shown in the Energy Targets group.
1.3.1 Range Targeting

One of the main objectives when creating a heat exchanger network is
to minimize the capital and operating costs. The minimum approach
temperature, DTmin, is a key parameter in defining the balance
between capital and operating costs. You can find the optimal value for
DTmin by performing a Range Targeting calculation.
1. On the Targets view, click on the Range Targets tab.
2. Click the Calculate button, located below the Range Targets tab,
to perform the calculations.
3. Click on the Plots page to view the plot, which displays the Total
Cost Index Target vs. DTmin, as shown in the figure below.
Figure 1.15
The
optimum
DTmin is
between
15°C and
25°C.
Click on the View After the calculations are

StandAlone Plot button to complete, the Calculate button is
open a view with only the replaced with Clear Calculations
plot. button.
4. To find a better approximation of the optimal DTmin value, you need

to narrow the calculations.
Click the Clear Calculations button to clear the plot before you
perform a new calculation.
5. Click the DTmin Range button.
The Range Targets view appears. This view allows you to specify the
range of calculations.
6. In the Lower DTmin cell, enter 15.
7. In the Upper DTmin cell, enter 25.
1-13
1-14 Examining the Targets
8. In the Interval Size cell, enter 0.5. This is the step size that will be
used between the lower and upper DTmin values.
The Range Target view should appear like the figure below:
Figure 1.16
9. Click the Calculate button. ExchangerNet automatically closes the

Range Target view and performs the new calculation. The results
indicate that the optimal DTmin value is 19.5°C.
Figure 1.17
10. To verify this value, click on the Table page.

11. Examine the values in the Total Cost Index column for the
minimum value. Move across the row to find the corresponding
DTmin value. It is 19.5°C.
The new plot shows that the optimal DTmin value is 19.5°C. For the
purpose of this application, however, leave the DTmin value at
10°C.
12. Click the Close icon to close the Targets view and return to the main
HI Case view.
Close icon
1-14
1.4 Building the Heat

Exchanger Network
1.4.1 Accessing the HEN Design
View
To access the heat exchanger network (HEN) design:
1. In the HI Case view, click the Open HEN Grid Diagram icon.
2. The Heat Exchanger Network (HEN) Design view appears with the
Open HEN Grid Grid Diagram tab active, as shown in the figure below.
Diagram icon
Figure 1.18
The Open Palette View icon allows you to access the Design Tools palette.
1-15
1-16 Building the Heat Exchanger
1.4.2 Modifying HEN Diagram

Properties
1. To open the Property Presets view, do one of the following:
• On the HEN Design view, click the Open Palette View icon. The
Design Tools palette appears. On the Design Tools palette, click
Open Palette View icon
the Open HEN Diagram Properties View icon.
OR
•Right-click on the Grid Diagram, and select Properties from the
Open HEN Diagram
Object Inspect menu.
Properties View icon 2. From the list in the Property Presets view, select Preset 4:
(Temperature). This property preset sorts the streams by their
temperatures and displays both process and utility streams.
3. Click the Edit button. The Property Preset: Preset 4 view appears.
Figure 1.19
4. Click the Annotations tab.
1-16
5. In the Heat Exchangers group, click the Middle drop-down list

and select Name as shown in the figure below.
The heat exchanger name will now appear above the heat
exchanger object in the Grid Diagram.
Figure 1.20
6. Click the Close icon to close the Property Preset 4:(Temperature)

view and the Property Presets view.
Close icon
1.4.3 Adding a Splitter

To maintain a logical order, you will place the heat exchangers in a
position similar to that shown on the Process Flowsheet. The crude oil
feed is split before it enters heat exchanger 10 and 6 on the Process
Open Palette View icon Flowsheet, so we must split the Desalter Feed stream.
To add heat exchangers, In this procedure, you will add a splitter to the Desalter Feed stream in
mixers and splitters, the
Design Tools palette must the flowsheet.
be available. 1. Click the Open Palette View icon, located in the bottom right
corner of the Grid Diagram tab.
The Design Tools palette appears.
Figure 1.21
Add Split icon
Bull’s eye icon
2. Right-click and hold on the Add Split icon.

Blue Dot icon 3. Drag the cursor over the Desalter Feed stream until the Bull’s eye
icon appears.
1-17
4. Now release the mouse button. The splitter appears as a solid blue
dot.
5. To expand the splitter, click the blue dot once. The stream will now
appear as shown in the figure below.
Figure 1.22
Each segment of the split is called a branch.
The Desalter Feed stream exchanges heat with the Light Naphtha
stream in exchanger 6 and the Fuel Oil stream in exchanger 10. You will
now place the first heat exchanger on the Desalter Feed stream.
1.4.4 Adding Heat Exchangers

Adding Heat Exchanger 6
In this procedure, you will place an exchanger between the Light
Naphtha stream and the Desalter Feed stream. This is Exchanger 6 on
the Process Flowsheet.
The streams on the Grid Diagram appear dashed because the

Heat Exchanger 6 energy in the streams has not been satisfied. As heat
exchangers are placed and stream energy is satisfied, the
lines representing the streams changes from dashed to solid.
1. In the Design Tools palette, right-click and hold on the Add Heat
Add Heat Exchanger icon Exchanger icon.
2. Drag the cursor to the top branch of the split on the Desalter Feed
stream until the Bull’s eye icon appears.
3. Release the mouse button. The heat exchanger appears as a sold
red dot.
4. Click and hold on the red dot, then drag the cursor to the Light
Bull’s eye icon Naphtha stream. A light blue dot will appear underneath the cursor
as you drag it to the new stream.
5. Release the mouse button. The heat exchanger appears.
Red Dot icon
Light blue dot icon

(under four arrows)
1-18
The Grid Diagram tab should now appear as shown in the figure
below.
Figure 1.23
ExchangerNet may appear to move the heat exchanger to the bottom

branch. If this happens, adding a heat exchanger to the second branch
later in the tutorial will result in Exchanger 6 showing on the top branch
(see Figure 1.27).
6. Double-click either end of the heat exchanger (the grey circles) to
open the Heat Exchanger Editor view.
7. Click the Notes tab.
8. In the Name field, type Exchanger 6.
9. Click the Data tab.
1-19
10. Click the Tied checkbox by the Desalter Feed stream (cold stream)
inlet temperature field. The view now appears as shown in the
figure below.
Figure 1.24
Hot Stream Hot Stream

Inlet Outlet
Temperature Temperature
Cold Stream
Downstream
Splitter
Temperature
Cold Stream (in this case,
Upstream Inlet
Mixer (Outlet) Temperature
Temperature
The Desalter Feed stream passes through the hottest part of

the Light Naphtha stream, therefore, you can tie the inlet
temperature of the hot stream entering the heat exchanger.
Since the Desalter Feed 11. Click the Tied checkbox by the hot stream inlet temperature field.
stream is being heated
from its initial inlet Before the calculation can occur, you must specify the cold stream
temperature, you can outlet temperature.
“tie” this value to the inlet
temperature value found 12. In the cold stream outlet temperature field, enter 121°C. This value
on the Process Streams comes from the Desalter Stream outlet target temperature on the
tab on the main HI Case Process Flowsheet.
view.
1-20
The heat exchanger now solves and appears as shown in the figure
All values in blue have below.
been entered by the user
and can be altered.
All values in black have Figure 1.25
been calculated by
ExchangerNet and cannot
be altered.
13. Click the Close icon to close the Exchanger 6 property view.
Close icon
Adding Heat Exchanger 10
Figure 1.26
Add Heat Exchanger icon
Heat Exchanger 10
Bull’s eye icon
Exchanger icon.
2. Drag the cursor to the empty branch of the split on the Desalter
Feed stream until the Bull’s eye icon appears.
Red Dot icon 3. Release the mouse button. The heat exchanger appears as a sold
red dot.
4. Click and hold on the red dot, then drag the cursor to the Fuel Oil
Light blue dot icon
stream. A light blue dot will appear underneath the cursor as you
drag it to the new stream.
(under four arrows)
1-21

The Grid Diagram tab should now appear as shown in the figure
below.
Figure 1.27
Top Branch
Bottom
Branch
6. Double-click on either end of the heat exchanger (the grey circles)

to open the Heat Exchanger Editor view.
8. In the Name field, type Exchanger 10.
According to the Process 10. Click the Tied checkbox by the Desalter Feed cold stream inlet
Flowsheet, the Desalter
Feed is being heated from
temperature field.
its inlet temperature of 11. In the Desalter Feed cold stream outlet temperature field, enter
15.6°C to its target
temperature, which is also
121°C, then press the ENTER key.
the mixer temperature of 12. In the empty hot stream outlet temperature field, type 120°C, then
121°C.
press the ENTER key. The exchanger solves.
We also know the Fuel Oil
stream temperature exits
1-22
Figure 1.28
13. Click the Close icon to close the property view.
ExchangerNet automatically calculates the inlet temperature of the hot

stream to be 232.7°C. From the Process Flowsheet, however, you know
that the temperature of the hot stream entering the exchanger should
be 167°C. In order to adjust this temperature, you must change the
balance of flows going through the splitter on the Desalter Feed stream.
Adjusting the Split Ratio

Before you adjust the split ratio, ensure the split ratio values are visible
on the Grid Diagram view.
1. On the Design Tools palette, click the Open HEN Diagram
Properties View icon. The Property Presets view appears.
Open HEN Properties 2. Click the New button. The New Property Preset view appears.
View icon
3. In the Name field, type Split Ratio, then press ENTER.
The Property Presets view reappears, and Split Ratio appears in the
list.
4. In the list, select Split Ratio, then click the Edit button.
The Property Preset: Split Ratio view appears.
6. In the Streams group, click the Segments drop-down list and select
Split Fraction.
7. Click the Close icon on both the Property Preset: Split Ratio view
and the Property Preset view to close them.
The split ratio values now appear on the Grid Diagram view for the
Desalter Feed stream. The default ratio is 0.5:0.5.
Now you will adjust the split ratio.
1-23
1. Double-click on either end of Exchanger 10 to open the heat

Remember, the heat exchanger view. You want this view open so you can observe the
exchanger views and Split
Editor view are Modal
changes in the hot stream inlet temperature.
views. To open all views, 2. Open the splitter view by double-clicking on either end of the
you have to click the Pin splitter. The Split Editor view appears as shown in the figure below.
icon and change the
Modal views to Non-Modal
views. Figure 1.29
3. Arrange the heat exchanger view and the Split Editor view so you
can see both views clearly.
To decrease the inlet temperature for Exchanger 10, you must transfer
less energy in the heat exchanger. An effective way of doing this is to
decrease the flow of the cold stream.
4. In the Split Editor view, Flow Ratios column, click in the top cell with
the blue text. Change the flow ratio value from 0.5 to 0.75 and
observe the inlet temperature change in the heat exchanger view.
The rows in the Branch 5. Continue to adjust the split ratio until the hot stream inlet
Streams table represent
the two branches of the temperature for Exchanger 10 is about 167°C. The split ratio will be
split. approximately 0.2 for Exchanger 10 and 0.8 for Exchanger 6.
Examine the Grid 6. Close the Split Editor view and the Exchanger 10 property views.
Diagram to confirm which
table row affects which
The line representing the Desalter Feed stream is now solid. This means
that this stream’s energy requirements have been satisfied.
Figure 1.30
7. Open the Property Presets view by clicking the Open HEN Diagram
Open HEN Properties Properties View icon in the Design Tools palette.
View icon
1-24
8. Select the Preset 4: Temperature to display the temperature

value above the streams for each segment.
9. Click the Close icon on the Property Preset view to close the view.
Adding Two Coolers

You will now place an air cooler on the Light Naphtha stream and a
cooler on the Fuel Oil stream.
1. Follow steps #1 through #5 in Section 1.4.4 - Adding Heat
Exchangers to add an air cooler between the Air stream and Light
Naphtha stream, downstream from Exchanger 6.
2. Open the Heat Exchanger Editor view by double-clicking on either
end of the newly inserted heat exchanger.
3. Click the Notes tab. In the Name field, type Air Cooler.
From the Process 5. Click the Tied checkbox by the hot stream inlet temperature field.
Flowsheet, you know the
air cooler cools the Light 6. Click the Tied checkbox by the hot stream outlet temperature field.
Naptha stream from the The heat exchanger now solves.
Exchanger 6 outlet
temperature of 107.9°C
to the stream target Figure 1.31
temperature of 71°C.
7. Add a cooler between the Fuel Oil stream and the Cooling Water
utility stream, downstream from Exchanger 10 on the Fuel Oil
stream.
From the Process 8. Open the Heat Exchanger Editor view by double-clicking on either
Flowsheet, you know the end of the newly inserted heat exchanger.
cooling water utility cools
the rest of the Fuel Oil 9. Click the Notes tab. In the Name field, type CW1.
stream from the 10. Click the Data tab.
Exchanger 10 outlet
temperature of 120°C to 11. Click the Tied checkbox by the hot stream inlet temperature field.
the stream target
temperature of 90°C. 12. Click the Tied checkbox by the hot stream outlet temperature field.
The exchanger solves.
1-25
The Fuel Oil and Light Naphtha streams should appear as shown in the
figure below.
Figure 1.32
1.4.5 Using the Worksheet to

Enter Heat Exchanger
Information
After the desalter operation, the crude oil is represented by the Pre-
Flash Feed stream. This stream will first pass through Exchanger 9 and
transfer heat with the Heavy Naphtha stream.
You can only add heat In the following procedure, you will use the Work Sheet tab to modify
exchangers in the Grid the heat exchangers:
Diagram tab.
1. Close any property views that are open.
2. Follow steps #1 through #5 in Section 1.4.4 - Adding Heat
Exchangers to add a heat exchanger between the Pre-Flash Feed
stream and the Heavy Naphtha stream.
1-26
3. On the HEN Design view, click the Work Sheet tab (see figure
below). The newly added heat exchanger is named E-104.
Figure 1.33
Double-clicking on any heat exchanger name or stream name will

open the property view of that heat exchanger or stream.
The “yellow
light” icon
indicates that
this heat
exchanger is not
fully specified
yet.
4. In the Heat Exchanger column, click in the cell with E-104 and
type Exchanger 9.
From the Process 5. In the Exchanger 9 row, click the checkbox in the Tied column
Flowsheet, you know that
beside the Cold T in column.
both the Heavy Naptha
stream and the Pre-Flash 6. Click the checkbox in the Tied column beside the Hot T in column.
Feed stream enter
Exchanger 9 at their inlet 7. Click in the Cold T out cell and enter 122°C. The final values are
temperatures. calculated and appear on the worksheet. The “yellow light” icon
You also know the Pre- disappears, indicating a fully solved heat exchanger.
Flash Feed stream exits
the exchanger at 122°C. 8. Click on the Grid Diagram tab.
9. To satisfy the rest of the energy in the Heavy Naphtha stream,
follow steps #1 through #5 in Section 1.4.4 - Adding Heat
Exchangers to add a heat exchanger between the Heavy Naphtha
stream and the Cooling Water utility stream.
10. Click the Work Sheet tab and rename the new exchanger CW2.
11. In the CW2 row, click the checkboxes in the Tied columns beside
the Hot T in and Hot T out columns. The exchanger solves.
1-27
1.4.6 Completing the Pre-Flash

Section
To complete the section between the desalter operation and the pre-
flash operation, four more exchangers and five coolers must be added.
You can do this by using just the Grid Diagram tab, or both Grid
Diagram and Work Sheet tabs.
Satisfying the Kerosene and Reflux

Streams
1. Add a splitter to the Pre-Flash Feed stream downstream from
Exchanger 9. Refer to steps #1 through #5 in Section 1.4.3 -
Adding a Splitter.
If necessary, refer to 2. Add a heat exchanger between the top branch of the split Pre-Flash
Section 1.4.4 - Adding
Heat Exchangers to
Feed stream and the Kerosene stream.
review the procedure for 3. Rename the new exchanger Exchanger 7.
adding a heat exchanger.
4. Click the Tied checkbox for both the hot and cold stream inlet
temperatures.
5. In the cold stream outlet temperature field, enter 163°C. This is
also the mixer temperature.
6. Add a heat exchanger on the other/empty branch of the Pre-Flash
Feed and connect the exchanger to the Reflux stream.
7. Rename the new exchanger Exchanger 8.
8. Click the Tied checkbox for both the hot and cold stream inlet
temperatures.
9. In the cold stream outlet temperature field, enter 163°C. This is
also the mixer temperature.
After the addition of these two exchangers, the Pre-Flash Feed
stream should appear similar to the figure below.
Figure 1.34
If necessary, refer to 10. Adjust the split ratio of the Pre-Flash Feed stream, if required.
steps #1 through #6 of
Adjusting the Split
Ensure that the hot stream outlet temperature of Exchanger 7 is
Ratio. 135°C, and the hot stream outlet temperature of Exchanger 8 is
169°C. The default split of 0.50 to each branch should be sufficient.
11. Add a heat exchanger between the Cooling Water utility and the
Reflux stream, downstream from Exchanger 8.
1-28
12. Rename the new exchanger CW3.

13. Click the Tied checkboxes for both the hot stream inlet and outlet
temperatures. The exchanger solves.
14. Add a heat exchanger between the Cooling Water utility and the
Kerosene stream, downstream from Exchanger 7.
15. Rename the new exchanger CW4.
16. Click the Tied checkboxes for both the hot stream inlet and outlet
17. Close any property views that are open.
Satisfying the Gas Oil Stream

1. Add a heat exchanger between the Pre-Flash Feed stream,
downstream from the splitter, and the Gas Oil stream.
2. Rename this heat exchanger Exchanger 5.
3. Click the Tied checkboxes for both inlet temperatures.
4. In the hot stream outlet temperature field, enter 210°C. This value
comes from the Process Flowsheet
5. Add another heat exchanger between the Gas Oil stream and the LP
Steam Generation utility, downstream from Exchanger 5.
6. Rename this heat exchanger BFW Heating 1.
7. Click the Tied checkbox for the hot stream inlet temperature only.
8. In the hot stream outlet temperature field, enter 172°C.
Heat Exchanger 5
9. Add one more heat exchanger between the Gas Oil stream and the
Cooling Water utility, downstream from BFW Heating 1.
10. Rename this heat exchanger CW5.
11. Click the Tied checkboxes for the hot stream inlet and outlet
1-29
Satisfying the Pre-Flash Feed Stream

This is the last heat exchanger required to satisfy the Pre-Flash stream.
1. Add a heat exchanger between the Pre-Flash Feed stream and the
Fuel Oil stream, upstream from Exchanger 10 on the Fuel Oil
stream.
2. Rename the heat exchange Exchanger 4.
3. Click the Tied checkboxes for the Pre-Flash cold stream inlet and
outlet temperatures.
4. In the hot stream inlet temperature field, enter 243°C. This
temperature come from the Process Flowsheet. The heat exchanger
solves.
The Grid Diagram tab and Work Sheet tab should now appear
similar to the figures below.
Figure 1.35
1-30
Figure 1.36
1.4.7 Completing the Heat

Exchanger Network
The rest of the heat exchanger network consists of heat exchangers to
satisfy the Fuel Oil stream and two furnaces. The furnaces will be
replaced with heaters on the Fired Heat (1000) stream.
1. Add a heat exchanger between the Fuel Oil stream and Crude Tower
Feed stream.
Ensure that you place the hot end of the heat exchanger
between the Fuel Oil stream inlet and Exchanger 4, not
between Exchanger 4 and Exchanger 10.
2. Rename the heat exchanger Exchanger 3.

The Fuel Oil stream should appear similar to the figure below.
Figure 1.37
temperatures, and for the cold stream inlet temperature. The heat
exchanger solves.
4. Add a heat exchanger between the Fuel Oil stream and the LP
Steam Generation utility, between Exchanger 4 and Exchanger 10.
5. Rename the exchanger BFW Heating 2.
1-31
7. Add the first of the fired heaters by placing a heat exchanger
between the Crude Tower Feed and Fired Heat (1000) utility,
downstream of Exchanger 3.
8. Rename this exchanger Furnace 1.
9. Click the Tied checkbox by the cold stream inlet temperature.
10. In the cold stream outlet temperature field, enter 265°C. The
exchanger solves.
11. Add the final heat exchanger between the same streams as in step
#4 above, downstream from Furnace 1.
12. Rename the exchanger Furnace 2.
13. Click the Tied checkbox for both cold stream temperatures. The
exchanger solves and all streams are satisfied.
The heat exchanger network is complete. The status bar on the Grid
Diagram tab will appear green, indicating that there are no unsatisfied
streams, and no uncalculated heat exchangers.
Figure 1.38
Confirm your heat exchanger with the completed HEN diagram and
1-32
worksheet as shown in the figures below.
Figure 1.39
When you examine all of the calculated values, you will notice that all
values are very close to those indicated on the initial Process
Flowsheet.
1.5 References
1
Linnhoff, B., Townsend, D.W., Boland, D., Hewitt, G.F., Thomas, B.E.A., Guy,
A.R., Marsland, R.H., A User Guide on Process Integration for the Efficient
use of Energy, IChemE England, 1982.
1-33
1-34 References
1-34
Data Extraction from UniSim Design 2-1
2 Data Extraction from

UniSim Design
2.1 Introduction .................................................................................. 2
2.2 Preparing for Data Extraction ........................................................ 5

2.2.2 Opening a HI Case or HI Project................................................. 6
2.2.3 Examining the Extraction Tips.................................................... 7
2.3 Editing the UniSim Design Case ..................................................... 8

2.3.1 Checking Mode & Solved Status of Unit Operations ....................... 9
2.3.2 Checking Stream & Unit Operation Names ..................................11
2.3.3 Checking Mixers & Splitters ......................................................13
2.4 Performing the Data Extraction ....................................................17

2.4.1 Performing the Initial Data Extraction ........................................17
2.4.2 Fixing Warnings in the UniSim Design Case ................................27
2.4.3 Performing the Final Data Extraction..........................................30
2.5 Adjusting the Extracted Data in ExchangerNet .............................30
2-1
2-2 Introduction
2.1 Introduction
One of the extremely useful features of ExchangerNet is its ability to
extract information from UniSim Design or Aspen Plus so that heat
integration analysis can be performed on a pre-built simulation, without
having to re-enter the information.
In this tutorial, you will examine one of the default UniSim Design cases
provided with ExchangerNet, and then extract the information into
ExchangerNet.
You must have UniSim Design version 350 or higher installed

on your computer in order to use this tutorial.
This tutorial assumes that you have used UniSim Design and
understand how to navigate through ExchangerNet. It is also assumed
that you have completed the HI Case or HI Project tutorial, and that
you understand how to create streams and create a heat exchanger
network using the Grid Diagram.
The UniSim Design case that will be extracted is a modified version of

the sample UniSim Design case G-2.usc. The file included with
ExchangerNet is named dataext.usc and can be found in the
Samples\UniSimDesignTest directory.
2-2
The UniSim Design flowsheet is shown in the figure below.
Figure 2.1
2-3
2-4 Introduction
The natural gas industry commonly uses tri-ethylene glycol (TEG) for
gas dehydration where low gas dew point temperatures are required,
such as in the design of offshore platforms in the Arctic or North Sea
regions or for other cryogenic processes.
The composition of the natural gas stream (Inlet Gas) has been
provided on a water-free basis. To ensure water saturation, this stream
is mixed with stream Water To Saturate. The water-saturated gas
stream Gas + H2O is then fed to a scrubber to knock out the free water.
This scrubbed stream (Gas To Contactor) is fed to the TEG Contactor,
where it is contacted with a regenerated lean TEG stream (TEG Feed).
Stream TEG Feed absorbs most of the water in the Gas To Contactor
stream. The rich TEG stream from the absorber bottoms (Rich TEG) is
heated to 220 °F by the hot lean TEG from the regenerator (Regen
Bttms), and is fed to the stripper column for regeneration. The stripper
column is a refluxed tower consisting of 3 stages plus a condenser. The
regenerated TEG is cooled and returned to the top of the TEG absorber.
For the purposes of demonstrating ExchangerNet capabilities to extract

UniSim Design data, the TEG only stream is being heated at the same
time that the pressure is greatly reduced. A multiple attachment has
been used to display two options, a heat exchanger using steam or a
valve.
A recycle operation is required to complete this simulation because the

lean TEG is being returned to the contactor. An initial estimate of the
lean TEG is required to run the contactor, and when the rest of the
simulation has been built, the regenerator will calculate the new lean
TEG. This stream is updated by the recycle operation.
2-4
2.2 Preparing for Data

Extraction
UniSim Design or Aspen Plus data can be extracted into either HI
Project or HI Case. Before performing a data extraction, it is always
wise to read the Extraction Tips so that you can find as many possible
problems in your simulation flowsheet before performing the first
extraction.

Before you begin, verify that the units currently selected in the
preferences are the ones you want to use. ExchangerNet will perform
the unit conversion calculations when it extracts the data from UniSim
Design, but it is easier to compare numbers if they use the same units.
1. Open UniSim Design (version 350 or higher).
2. Open the case dataext.ucs, included in the
\Samples\UniSimDesignTest directory of your ExchangerNet
program.
3. In the UniSim Design Tools menu, select Preferences. The
Session Preferences view appears.
4. Click the Variables tab, then click the Units page. The Unit Set
Name should be SI. If it isn’t, select SI in the Available Unit Sets
list.
Figure 2.2
2-5
2-6 Preparing for Data Extraction
5. From the Windows Start menu, open ExchangerNet.

6. In ExchangerNet, repeat steps #3 and #4 to set the units to match
the UniSim Design case.
7. Save the modified case under a new name, such as
newDataEXT.usc. Do not save any changes over the original case.
Before you can examine the extraction tips, open the HI Case view or
HI Project view.
2.2.2 Opening a HI Case or HI

Project
1. To access the HI Case view or HI Project view, do one of the
following:
• From the Features menu, select HI Case or HI Project.
• From the Managers menu, select Heat Integration Manager. The Heat
Integration Manager view appears. In the left column, select HI Case or HI
Project, then click the Add button.
• On the tool bar, click the Heat Integration Manager icon. The Heat
Integration Manager view appears. In the left column, select HI Case or HI
Project, then click the Add button.
Heat Integration
Manager icon The HI Case view or HI Project view appears.
Figure 2.3
HI Case view
2-6
Figure 2.4
HI Project view
You are now ready to look at the extraction tips.
2.2.3 Examining the Extraction

Tips
In the HI Case view, the Data Extraction icon appears only on the
Process Streams tab. In the HI Project view, it appears on the Process
Streams page of the Data tab.
2-7
2-8 Editing the UniSim Design Case
1. Click the Data Extraction icon. The Extraction Wizard appears.
Figure 2.5
Data Extraction icon
2. Click the Tips button. The Extraction Tips view appears.
Figure 2.6
Read all tips carefully before continuing to the next section, as you will
be manipulating the case based on these tips. It is good practice to read
these tips before every extraction. This will allow you to find some if not
all of the errors before you perform the data extraction.
2.3 Editing the UniSim Design

Case
Before you extract information from UniSim Design, you will use the
tips you just reviewed to check the UniSim Design case to be extracted
to find possible problems. Although ExchangerNet will produce
warnings about many of the issues in UniSim Design, it will not produce
messages about others that can result in incorrect targets, such as
2-8
repeated names.
2.3.1 Checking Mode & Solved

Status of Unit Operations
In order to extract a UniSim Design case into ExchangerNet, the case
must be in steady state mode (tip 3) and the entire flowsheet must be
solved (tip 2). Since these conditions are very easy to check, and
absolutely essential to the extraction, they will be checked first.
1. Ensure that the UniSim Design case to be extracted is open and that
you’ve set the unit preferences as described in steps #1 and #2 in
Section 2.2.1 - Setting Unit Preferences.
2. On the UniSim Design tool bar, ensure that the Steady State Mode
icon is active, as shown in the figure below.
Figure 2.7
Steady State Mode icon
The sample case should be in steady state mode. If it is not, click

the Steady State Mode icon, and ensure that the case converges.
3. On the flowsheet, verify that all streams and unit operations have
been solved by doing one or both of the following:
• Examine all streams and unit operations. All material streams should
appear dark blue, all energy streams should appear dark red, and all unit
operations should be outlined in black.
Figure 2.8
An example of a “solved” An example of an “unsolved”

unit operation and attached unit operation and attached
streams streams
2-9
• Check the Object Status Window at the bottom left corner of the window
for error messages.
Figure 2.9
The sample case provided is solved. However, if the sample case is not
solved, check the following:
• Check the Trace Window for the streams or operations that are
missing information.
• If the Trace Window is empty, and the flowsheet is not solved, it
could be because the solver is not active. Click the Solver
Active icon.
Solver Active icon • Check your UniSim Design manuals for more information on how
to solve flowsheets.
• Check that there are no extra unit operations or streams in the
flowsheet (tip 1).
Remove the Valve and Extra Stream

In the sample case DataEXT.usc, all of the operations and streams are
directly related to the flowsheet (i.e., there are no streams and unit
operations forming a second system). The stream TEG only however,
has a multiple attachment to a valve and a heat exchanger. Since
multiple attachments pose problems for ExchangerNet, and the valve
will not result in any changes to the network built in ExchangerNet, nor
the targets calculated, remove the valve and extra stream.
2-10
1. Disconnect stream TEG only from valve VLV-101.

These items may already
be removed from the 2. Delete valve VLV-101and the material stream TEG out.
sample case.
2.3.2 Checking Stream & Unit

Operation Names
Checking for Duplicate Names
Multiple tips warn of extraction problems due to streams and unit
operations having the same name, either within one flowsheet or
across multiple flowsheets (tips 6, 8, 9,). The easiest way to check for
this is by using the Object Navigator.
1. Access the Object Navigator by doing one of the following:
• On the toolbar, click the Object Navigator icon.
• In the Flowsheet menu, select Find Object.
Object Navigator icon • Press the F3 hot key.
2. Search for unit operations and streams that have the same name.
In the Flowsheets group, select the main flowsheet. In the Filter
group, click the All radio button. This will display all unit operations
and streams. The Object Navigator appears as shown in the figure
below.
Figure 2.10
This may already be 3. Scroll down the Flowsheet Objects list. There are two objects
corrected in the sample
case. named E-100. If you look on the flowsheet, you will find that there
is a heat exchanger and a stream with this name. Rename the
stream to TEG out.
4. Using the Object Navigator, repeat step #2 to ensure that there are
no other multiple names. In this case there are none. This takes
care of tip 9.
2-11
Checking for Streams that Span Multiple

Flowsheets
1. Use the Object Navigator to check for names that appear in more
than one flowsheet.
• All the inlet and outlet streams entering and exiting each column are
subject to this rule.
• Look for any stream that contains a heat exchanger in both the main
flowsheet and the sub-flowsheet.
2. Examine the Regen Feed stream. In the main flowsheet, the Regen
Feed stream exits a heat exchanger before entering the TEG
Regenerator sub-flowsheet, which appears in the following figure. In
this sub-flowsheet, however, there is no exchanger on the Regen
Feed stream, so it will not pose a problem.
Figure 2.11
3. Open the TEG Regenerator sub-flowsheet. The streams Sour Gas

and Regen Bttms exit the condenser and reboiler, respectively.
• The Sour Gas stream does not have any exchangers on it on the main
flowsheet so it will not pose any difficulties.
• The Regen Bttms stream, however, enters a heat exchanger in the main
flowsheet. ExchangerNet uses the stream entering the reboiler and
returning to the column during extraction, so there will be no stream
duplication in this case.
4. Return to the main flowsheet. The Dry Gas stream exiting the T-
100 column is entering a heat exchanger.
5. Open the T-100 column sub-flowsheet. There is no reboiler or
condenser on this column, as it is acting as an absorber, therefore,
this will not create a stream duplication.
6. Use the Object Navigator to see if there are any internal streams
existing within any sub-flowsheet that do not represent a real
stream.
2-12
• To do this, highlight each sub-flowsheet in the Flowsheets group of the

Object Navigator, then select the Stream radio button in the Filter group.
• This will display all material streams existing in the flowsheet. All internal
streams will be extracted as real streams.
• In this case, all of the internal streams do represent real streams in the
process. Since the reboiler and condenser must be taken into account, no
changes are required.
• If there are streams that you do not want extracted, you will have to
manually delete them after the data extraction.
2.3.3 Checking Mixers & Splitters

The last items to check before performing the data extraction in UniSim
Design are mixers and splitters. Check for non-isothermal mixers (tip
10). In this case, there are no multiple splitters or mixers in series,
however, there are two mixers that should be checked to see if they are
isothermal.
1. Open the property view for the Saturate mixer, and click on the
Worksheet tab.
Figure 2.12
2-13
The temperatures of the two inlet streams, Inlet Gas and

Water to Saturate, are not the same temperature, so the
Water to Saturate stream should be cooled down to the
temperature of the Inlet Gas and the mixer outlet stream
Gas + H2O, before it enters the mixer.
2. Create a new material stream named Water In. Copy all of the
information from the Water to Saturate stream by using the Define
from Other Stream button.
3. Add a cooler named Water Cooler. Its inlet stream is the Water In
stream you just created, and its outlet stream will be a new stream
named Water to Mixer. Define an energy stream named Q-200.
4. On the Design tab of the cooler property view, click on the
Parameters page, and define a pressure drop of 0 kPa.
5. Click on the Worksheet tab. In the Water to Mixer Temperature
field, enter 29.44°C to make it the same as the mixer inlet stream
temperature. The Water Cooler property view appears as shown in
the figure below.
Figure 2.13
6. Close the Water Cooler property view.

7. Open the Saturate mixer property view.
8. Click the Design tab, then click the Connections page.
9. Click in the inlets stream cell Water to Saturate, and from the
drop-down list, select the Water to Mixer stream. Also, define a new
outlet stream named Mixer Outlet. This should be done because,
even if the inlet temperatures are identical, the outlet temperature
can be different than the original outlet stream due to phase
changes.
The first part of the flowsheet will now calculate. The rest of
the flowsheet will not be calculated.
2-14
10. As per (tip 1), delete the now unnecessary Water to Saturate
stream.
11. Move the cursor over the Mixer Outlet stream. The fly-by for the
Mixer Outlet stream indicates that the calculated temperature is
28.69°C. This is less than the original outlet temperature of the Gas
+ H2O stream, which is 29.44°C. Therefore, a heater is required
between these two streams.
12. Add a heater with the name Gas + H2O Heater, and set the inlet
stream as Mixer Outlet, outlet stream as Gas+H2O, and an energy
stream as Q-201.
13. On the Design tab, click on the Parameters page, and define a
pressure drop of 0 kPa.
14. The entire flowsheet should now recalculate.
15. Close all property views.
You will now check the second mixer to see if it is non-isothermal.

16. Open the property view for the MakeUp mixer, and click on the
Worksheet tab.
Figure 2.14
In this case, the stream MakeUp TEG must be heated up to

the mixer outlet temperature.
17. Using the same procedure as step #2, create a stream named Cool
MakeUp TEG based on the information in the stream MakeUp TEG.
18. Add a heater named Heat MakeUp TEG. Set the inlet stream as Cool
MakeUp TEG and define the new outlet stream as MakeUp TEG to
Mixer. Define a new energy stream as Q-202.
19. On the Design tab, click on the Parameters page, then define a
pressure drop of 0 kPa.
2-15
20. On the Worksheet tab, enter the MakeUp TEG to Mixer

temperature as 145.07°C. This is the same as the other mixer inlet
stream.
21. Close the Heat MakeUp TEG heater property view, and re-open the
MakeUp mixer property view (if not already open).
22. On the Design tab, click on the Connections page. Replace the
outlet stream with a new stream TEG from Mixer, and replace the
inlet stream MakeUp TEG with the stream MakeUp TEG to Mixer.
23. Delete the now unnecessary stream MakeUp TEG.
24. Close all property views.
25. Move the cursor over the TEG from Mixer stream. The fly-by for the
TEG from Mixer stream indicates that the temperature calculated is
145.1°C. This is the same as the two inlet temperatures. So, you do
not need to heat or cool this stream.
26. Open the property view for the pump P-100. On the Connections
page of the Designs tab, replace the inlet stream TEG to Pump with
the stream TEG from Mixer. Delete the stream TEG to Pump. The
entire flowsheet should solve at this point.
27. If you want, you can manipulate the PFD to make it appear neater.
28. Save the modified UniSim Design case (renamed in step #7 of
Section 2.2.1 - Setting Unit Preferences). Do not save over the
original case.
29. Close UniSim Design.
This is all of the work that will be performed on this particular case
before performing the first extraction. It is important to remember that
in other cases, you will also have to deal with LNG exchangers. It is also
important to remember that the extraction cannot perform perfectly on
the first attempt. After the extraction is complete, the warning section
will indicate that more changes are required to our UniSim Design
flowsheet.
2-16
2.4 Performing the Data

Extraction
2.4.1 Performing the Initial Data
Extraction
1. If you have closed ExchangerNet, re-open it at this time.
2. Open a new HI Project. Data extraction can also be performed in
HI Case, but for this tutorial you will use HI Project.
3. Click the Data Extraction icon. The Extraction Wizard appears.
Data Extraction icon Figure 2.15

The Extraction Wizard
takes you through the
following steps for the
extraction process:
• Select File
• Set Options
• Select Flowsheet
• Modify Utilities
• Modify Heaters
• Modify Coolers
• Economic Data
4. Click the Next button. The next page appears, where you can select
the utilities file, economic file, and the simulation file.
2-17
2-18 Performing the Data Extraction
Select File (Step 1 of 7)

The data extraction process requires utility and economic information in
order to perform the extraction and the costing target calculations.
ExchangerNet automatically selects the default utility and capital cost

default files, but you can change the selection if required.
You can click the Browse 1. For the Utility File and Capital Cost File, accept the default selection.
button to select different
files for the utility and
capital cost data. Figure 2.16
2. In the bottom group, select the UniSim Design radio button.

3. Click the Browse button and locate the file you saved in step #28 in
Section 2.3.3 - Checking Mixers & Splitters.
4. Click the Next button to set detailed options for extraction.
2-18
Set Options (Step 2 of 7)

You can select different options that will affect the way in which the
data is extracted.
1. Ensure that the following options are set:
• The Only streams with phase changes checkbox is checked.
• All checkboxes in the Live Steam group are checked.
• The Ignore radio button is selected in the Pumps, Recycle
Blocks, and Pipe Segments group.
Figure 2.17
2. Click the Next button to select the flowsheet(s) to be extracted.
2-19
Select Flowsheet (Step 3 of 7)

The data from the selected flowsheet(s) is exported. When you click the
Next button after setting the options, ExchangerNet starts UniSim
Design running and will extract the data.
1. Wait until the Extraction Wizard (Step 3 of 7) view appears as
shown in the figure below.
Figure 2.18
2. In this tutorial, you will be extracting data from all three different
flowsheet. So make sure all the checkboxes under the Selected
column are checked.
3. Click the Next button to see the utilities to be added.
Modify Utilities (Step 4 of 7)

The utilities listed on this page are used in the extraction.
Figure 2.19
2-20
1. If you want to modify the utilities to be added, click the Modify

button.
When you click the Modify button, the text changes to blue
colour. The blue colour indicates you are allowed to change
the utilities. The Modify button is replaced by the Lock
button. When you click the Lock button, the text changes to
black and it cannot be modified.
2. You can also add more utilities by clicking the down arrow in the
<empty> cell and selecting the new utility from the drop-down list.
3. In this tutorial, the default utilities selected by ExchangerNet are
sufficient and do not require any modification.
4. Click the Next button to see the utilities to be used with the
heaters.
2-21
Modify Heaters (Step 5 of 7)

On this page, you can modify the default utility matched with each
heater.
Figure 2.20
1. If you want to modify the default utility matched with each heater,
click on the cell under the Utility column.
2. Open the drop-down list in the cell and select the utility you want.
3. In this tutorial, the default utilities selected for the heaters are
4. Click the Next button to see the utilities to be used with the coolers.
2-22
Modify Coolers (Step 6 of 7)

On this page, you can modify the default utility matched with each
cooler.
Figure 2.21
1. If you want to modify the default utility matched with each cooler,
click on the cell under the Utility column.
2. Open the drop-down list in the cell and select the utility you want.
3. In this tutorial, the default utilities selected for the coolers are
4. Click the Next button to see the economic data for the heat
exchangers.
2-23
Economic Data (Step 7 of 7)

The Reset button allows On this page, you can see and modify the type of economic data to be
you to reset to the default
values. used for all stream matches in the heat exchanger network.
Figure 2.22
1. If you want to edit the economic data for the heat exchanger, click
the Edit Economic Data button. The Heat Exchanger Capital Cost
view appears.
Figure 2.23
2. In this tutorial, the default economic data the heat exchangers are
3. Click the Close icon to close the Heat Exchanger Capital Cost view,
and return to the Extraction Wizard (Step 7 of 7).
Close icon
2-24
4. Click the Next button. A message appears indicating that the

UniSim Design file was extracted successfully.
Figure 2.24
5. Click the Finish button, and the Summary view appears as shown
in the figure below.
Figure 2.25
2-25
6. Click on the Report tab, and read the report carefully.

• The first section of the report displays the new streams that have been
created in ExchangerNet and the corresponding streams in the UniSim
Design case.
• The second section displays the utility streams that have been selected
from the list of default utilities in order to satisfy the heat load on the
heaters and coolers.
• The third section displays warnings of any potential problems that were
found in the UniSim Design case, and any heat exchangers that could not
be placed properly. The warning section should have the warnings as
Figure 2.26
7. Close the Summary view.
You can review the Summary view at any time in HI Project

by clicking the Data Extraction Report button on the Notes
tab when you select the Scenario level in the Viewer group.
Since there are still some problems in the UniSim Design case, you will
return to it and fix the problems. The data will have to be extracted
again after the new modifications to the UniSim Design flowsheet, so
there is not much sense in examining the data extracted at this point.
2-26
2.4.2 Fixing Warnings in the

UniSim Design Case
The UniSim Design case should be open because ExchangerNet
automatically opens it during the data extraction process.
1. The first warning is about the tolerances on the Recycle operation.
In UniSim Design, open the property view for this operation. Click
the Parameters tab, then click the Variables page.
2. Reduce the Composition tolerance.
• The Composition tolerance is 10, as indicated in the warning. The
composition tolerance should always be 1.0 or less, however, altering the
tolerances can result in an unsolved flowsheet.
• Begin by reducing the tolerance to 1.0. The flowsheet should still solve.
• Continue to reduce the tolerance by 0.1, ensuring that the flowsheet
continues to solve. You should be able to reach a tolerance of 0.1.
3. Reduce other tolerance values.
• Some of the other tolerances are quite high. Although this will not affect
the data extraction process, it can improve the results within the UniSim
Design case.
• Reduce the tolerances as indicated in the table below. The flowsheet
should still solve as shown in Figure 2.27.
Variable Tolerance
Vapour 0.01
Fraction
Temperature 0.5
Pressure 0.5
Flow 0.5
Enthalpy 0.5
Composition 0.01
Figure 2.27
2-27
4. Close the Recycle property view.

The second warning was about a temperature enthalpy reversal.
The streams listed are around the heat exchanger E-100.
5. Open the property view for heat exchanger E-100.
6. Click the Worksheet tab. The Steam In temperature is lower than
the Steam Out temperature. This does not make sense, since the
steam is acting as the hot stream and should be cooling down in
temperature.
Figure 2.28
2-28
7. To solve the problem, set the Steam Out temperature lower than
the Steam In temperature. In the Temperature cell of the Steam
Out column, enter 148°C.
The Status bar in the E-100 property view turns yellow and
indicates a Heat Unbalanced problem.
Figure 2.29
8. In the Temperature cell of the TEG Out column, enter -8°C. This
should solve the converge from wrong direction problem.
9. The entire flowsheet should solve.
10. Close the E-100 property view.
11. Save the modified case.
Although this should now take care of the warnings listed in the Data
Extraction report, there is one more potential problem.
Steam is used in the heat exchanger E-100. Even though this is a utility
stream it will be extracted as a process stream. There are two options
in this case. The first is to make E-100 a heater, which will
automatically cause ExchangerNet to select a utility for it. The second is
to manually replace the heat exchanger in UniSim Design with a heater.
For now, leave the UniSim Design case as it is and you will manipulate
the data in ExchangerNet after the next data extraction.
You are now ready to extract the information from UniSim Design
again.
2-29
2-30 Adjusting the Extracted Data in
2.4.3 Performing the Final Data

Extraction
You do not have to close the UniSim Design case to perform the data
extraction. Leave UniSim Design open and return to ExchangerNet.
1. Create a new HI Project. Re-extracting the data into an existing
project will generate inaccurate results.
2. Perform the steps in Section 2.4.1 - Performing the Initial Data
Extraction. When the extraction Summary view appears again,
read the report carefully. It should no longer display any warnings.
2.5 Adjusting the Extracted

Data in ExchangerNet
Now that all of the UniSim Design information has been extracted into
ExchangerNet, you can examine the newly created streams in the heat
exchanger network.
1. In HI Project, click on the Scenario level in the Viewer group.
2. Click the Data tab, then click the Process Streams page. Eleven
streams have been extracted, however, one stream will be manually
deleted as it is actually a utility stream, as noted after step #11 in
Section 2.4.2 - Fixing Warnings in the UniSim Design Case.
3. Before deleting the Steam stream, examine the Grid Diagram to see
if there are any exchangers on this stream.
4. In the Viewer group of the main HI Project view, click on the
SimulationBaseCase design.
5. On the Grid Diagram, locate the stream Steam_In_to_Steam_Out.
There is one heat exchanger on this stream that is matched with the
stream TEG_only_to_TEG_out. When the Steam stream is deleted,
this stream will become unsatisfied.
6. In the Viewer Group, click the Scenario level and return to the
Process Streams page on the Data tab.
7. Select the stream Steam_In_to_Steam_Out, then press the DELETE
key on the keyboard.
8. Click the Utility Streams page. There are utilities that have been
Open Palette View icon added during the extraction process, including three steam utilities,
so a utility will not have to be added to take into account the stream
that was deleted.
9. Return to the SimulationBaseCase design.
Open Property Preset View
icon
10. Click the Open Palette View icon in the lower right-hand corner of
the Grid Diagram tab. The Design Tools palette appears.
2-30
11. Click the Open Property Preset View icon. The Property Presets
view appears.
12. Select Preset 6: Alphabetical, which orders the streams
alphabetically and shows the utility streams. Close the Property
Presets view.
13. Add a heat exchanger between the TEG_only_to_TEG_out stream
and the utility stream LP steam.
14. Open the heat exchanger property view.
15. Click the Tied checkbox for both of the cold process stream
temperatures. The heat exchanger will solve. The network status
bar turns green, and all streams and heat exchangers are
completely satisfied and solved.
The data extraction process is now complete. All required adjustments

to the UniSim Design flowsheet were performed, and no warnings
appeared in the extraction summary report. Changes were made to the
process stream data in ExchangerNet to account for duplicate streams,
and the heat exchanger network was completed by adding the final
heat exchanger. You can now be confident that the targets calculated
by ExchangerNet are accurate, and can continue on in the analysis of
the existing network, or can perform changes to improve the network.
2-31
Automatic HEN Design in HI Project 3-1
3 Automatic HEN Design

in HI Project
3.1 Introduction .................................................................................. 2
3.1.1 Navigating Through HI Project ................................................... 3
3.2 Creating a HI Project for Automatic Design Generation ................. 7

3.2.2 Creating the HI Project ............................................................. 8
3.2.3 Entering Process Stream Data.................................................... 9
3.2.4 Entering Utility Stream Data .....................................................11
3.3 Generating HEN Designs ...............................................................13
3.4 References....................................................................................16
3-1
3-2 Introduction
3.1 Introduction
This tutorial serves two functions:
• Introduces the ExchangerNet Heat Integration (HI) Project
environment.
• Demonstrates how to use the Recommend Designs feature to
automatically generate Heat Exchange Network (HEN) designs.
If you are a new user to
In this tutorial, you will create an ExchangerNet HI Project, enter
ExchangerNet, it is highly
recommended that you stream and utility information, then use the ExchangerNet Recommend
complete the Crude Pre- Designs feature to automatically generate heat exchanger network
Heat Train Network
tutorial (refer to Chapter designs.
1 - Crude Pre-Heat
Train Network) before To demonstrate ExchangerNet’s ability to optimize HEN designs, you will
starting this tutorial.
build a very simple network that will be far above the target values,
It is assumed that you
know how to add and then use the Recommend Designs feature to optimize the network
complete heat exchangers design.
on the Grid Diagram tab.
ExchangerNet provides you with a self-contained environment where
you can create a HI Project with multiple Scenarios and Designs.
At the Project level, you define what you want to design. Within each
Project, there can be numerous Scenarios and Designs, as shown in the
figure below.
Figure 3.1
Project
Scenario 1 Scenario 2 ....................... Scenario n
Design 1
Design 2
.......
Design j
3-2
The Project level contains only the most general description of the
problem set being examined.
The Scenario level contains the assumptions, conditions, and

information required to generate a design. These conditions include
process stream specifications, utility streams, and economic factors.
The Design level contains the generated HEN design solutions. A

Scenario can contain multiple designs. The generated designs are
determined by the conditions, assumptions and specifications defined
at the Scenario level.
3.1.1 Navigating Through HI

Project
The Heat Integration Project View
The Heat Integration Project view in ExchangerNet is divided into three
sections: the Viewer group, the Main pane, and the Worksheet pane.
The three sections are displayed and labeled in the figure below.
Figure 3.2
Viewer
group
Main pane
Worksheet
pane
3-3
3-4 Introduction
Viewer Group
The Viewer group is always visible in the Heat Integration (HI) Project
view and contains the ExchangerNet tree browser, which is used to
access, create and delete Scenario and Design levels within a HI
Project.
To expand or compress the tree, click on the + or - beside the level you
want to view.
Figure 3.3
When you create a new HI Project, ExchangerNet automatically creates

a Scenario and Design level.
Main Pane
At the Scenario level, the Main pane displays a plot. You can select the
type of plot to display from a drop-down list at the top of the view.
At the Design level, the Main view displays the Heat Exchanger Network
(HEN) diagram.
Worksheet Pane
The Worksheet pane of the HI Project view displays the entered and
calculated values at the Design level.
3-4
The following sections describes some of the commonly used tabs

available at the Scenario and Design levels of the HI Project view.
Scenario Level
The following table lists and describes the tabs found at the Scenario
level.
Tab Description
Data tab On this tab, you enter all process and utility
stream data and set the cost parameters.
Targets tab All three pages on this tab contain the target
values calculated by ExchangerNet. These values
represent the performance of an ideal heat
exchanger network design for the entered stream
and economic data.
Range Targets tab The options on this tab are useful for determining
the optimal minimum approach temperature, or
DTmin, value. Click the Calculate button, and
use the plot or the table to find the DTmin value
for a minimum area or minimum cost value. For
more information, refer to Section 1.3.1 - Range
Targeting.
Designs tab Use this tab to compare all designs within a
Scenario. Here, you can display all designs or
display only completed designs. You can also
display the designs as a percentage related to the
target values.
Options tab Use this tab to manipulate the utility load
allocation method and access the utility and HTC
databases.
Notes tab Use this tab to enter notes for the Scenario level.
Design Level
To view the Design level, expand the tree in the Viewer group. To do
this, click the + beside the Scenario folder. Any designs contained
within the Scenario appear in the tree.
3-5
3-6 Introduction
To view a design, click the design name. The Main pane now displays a
Grid Diagram instead of a plot.
Figure 3.4
The following table lists and describes the tabs found at the Design
level.
Tab Description
Performance tab This tab displays the performance information for
all heat exchangers and utilities in the design.
Worksheets tab As in HI Case, this tab provides an alternative way
to manipulate the heat exchangers on the Grid
Diagram.
Heat Exchangers tab This tab displays detailed information about each
heat exchanger. When the Show All checkbox is
checked, this tab shows all heat exchangers.
When the checkbox is unchecked, only solved
exchangers appear.
Targets tab This tab shows all the same targets information
available at the Scenario level.
Notes tab This tab displays notes for a particular design. This
tab also contains a Modification Log page, which
automatically records and displays all
modifications made to the Grid Diagram.
Now that you have an understanding of the setup and structure of the
HI Project views, you are ready to begin the tutorial.
3-6
3.2 Creating a HI Project for

Automatic Design
Generation
To use ExchangerNet’s In the following sections you will set unit preferences, create the HI
Recommend Design
feature, the HI Project
Project, and enter process and utility stream data.
must contain all required

process stream data and
utility streams that are
sufficient to satisfy the
energy demands of the
In this section, you will define a new unit set. For this tutorial, the
temperatures are in Celsius, and the MCp is in kJ/C-s.
1. Start the ExchangerNet program, if it is not already open.
2. From the Tools menu, select Preferences. The Session
Preferences view appears.
3. Click the Variables tab, then select the Units page.
The current set does not 4. In the Available Unit Sets list, select the unit set SI, then click the
use the units required for
this tutorial, so you will Clone button. This will create a cloned unit set named New User.
create a new set and 5. In the Unit Set Name field, rename the New User set to
modify the units.
Application 2 Units.
6. In the Display Units group, scroll down the list to find the Energy
units cell. The default unit is kJ/h.
7. In the Energy unit cell, click the down arrow. A drop-down list
appears containing various unit options as shown in the figure
below.
Figure 3.5
The unit kJ/s is equal to

kW, so in some cases you
can choose which units
you want to display.
8. From the drop-down list, select kJ/s.
3-7
3-8 Creating a HI Project for Automatic
9. In the Display Units group, scroll to the MCp cell.

10. In the MCp cell, click the drop-down arrow and select kJ/C-s.
11. Scroll through the rest of the list and change the units for the
following variables:
• Ht Tran Coeff (kJ/s-m2-C)
• Heat Flux (kJ/s-m2)
• Fouling (C-m2/kW)
• Enthalpy per Length (kJ/s-m)
• Power (kJ/s)
Although some of these variables may not be used, it is always a
good idea to keep all of the units consistent.
12. Optional: At this point you can save the newly created preference
set, which will allow you to use it for future cases.
To save, click the Save Preference File icon. On the Save
Preference File view, enter a file name and location, then click the
Save button.
Save Preference File icon
Although you can 13. Click the Close icon to close the Session Preferences view.
overwrite the default
preference set included
with ExchangerNet, it is
not recommended. 3.2.2 Creating the HI Project
In this section you will create the Heat Integration (HI) Project.
To access the HI Project view, do one of the following:

• From the Features menu, select HI Project.
• Click the Heat Integration Manager icon, or, from the
Managers menu, select Heat Integration Manager. The
manager view appears. In the left list, select HI Project, then
click the Add button.
icon
3-8
The HI Project view appears.
Figure 3.6
You should
be at the
Scenario
level in the
Viewer
group.
In the
Worksheet
pane, you
should be on
the Process
Streams
page of the
Data tab
3.2.3 Entering Process Stream

Data
In this section you will enter data for the process streams.
1. Ensure that you are in the Scenario view, Data tab, Process
Streams page.
2. In the Name column, click on **New**.
3. Type h1, then press the ENTER key. The cursor automatically moves
to the Inlet T cell.
4. In the Inlet T cell enter 230°C. The default units that appear in
the unit drop-down list are already the desired unit, degrees
Celsius, so they do not need to be changed.
5. In the Outlet T cell, enter 80°C.
If you know the temperature in a unit other than the default, type
the known temperature in the cell, then select the appropriate units
from the drop-down list, as shown in the figure below.
3-9
ExchangerNet automatically converts the value to the default units.

For example, if you enter 176°F, ExchangerNet converts this value
to 80°C.
Figure 3.7
6. In the MCp cell, enter 30 kJ/°C-s.

7. In the HTC cell, enter 0.4 kJ/s-m2-C.
After you enter the inlet and outlet temperatures, ExchangerNet knows
if the stream type is hot or cold. A red or blue arrow appears in the
second column. A red arrow indicates a hot stream; a blue arrow
indicates a cold stream.
Next you will add more streams to the HI Project.
Using the procedure you just learned, enter the data for following
process streams. The stream information provided is from U. Shenoy
(1995)1.
Inlet T Outlet T MCp (kJ/ HTC (kJ/s-

Name
(°C) (°C) °C-s) m2-C)
h2 200 40 45 0.4
c3 40 180 40 0.4
c4 140 280 60 0.4
h5 110 45 0.1 0.4
h6 115 40 0.1 0.4
h7 105 40 0.1 0.4
h8 110 42 0.1 0.4
h9 117 48 0.1 0.4
h10 103 50 0.1 0.4
c11 170 270 0.1 0.4
c12 175 265 0.1 0.4
c13 180 275 0.1 0.4
c14 168 277 0.1 0.4
c15 181 267 0.1 0.4
h16 110 45 0.1 0.4
h17 115 40 0.1 0.4
h18 105 40 0.1 0.4
3-10
Inlet T Outlet T MCp (kJ/ HTC (kJ/s-

Name
(°C) (°C) °C-s) m2-C)
h19 110 42 0.1 0.4
h20 117 48 0.1 0.4
h21 103 50 0.1 0.4
c22 170 270 0.1 0.4
c23 175 265 0.1 0.4
c24 180 275 0.1 0.4
c25 168 277 0.1 0.4
c26 181 267 0.1 0.4
h27 115 42 0.1 0.4
h28 117 43 0.1 0.4
8. Verify that the information you just entered on the Process

Streams page matches the figures in the table above.

In this section, you will specify all the required heating and cooling
utilities for the HEN design.
1. On the Data tab, select the Utility Streams page.
The hot and cold status bars at the bottom of the tab display
“insufficient”, which means there are not enough cold and
hot utilities to satisfy the process streams.
Click the drop-down 2. First you will define the hot utility. In the Name column, click in the
arrow in the Name <empty> cell. Type hu, then press ENTER.
column to view a list of
default utilities available 3. Click in the Inlet T cell and enter 400°C.
within ExchangerNet.
4. Click in the Outlet T cell and enter 350°C. This is the minimum
Usually, you would use
these values, but for this information required for a utility.
tutorial you will define the
utilities manually.
The hot utility is now sufficient, which means that the hot
utility entered has enough energy to heat all of the cold
process streams.
5. Click in the HTC cell and enter 0.4.

6. Now you will define the cold utility. In the Name column, click in the
<empty> cell and type cu.
7. In the Inlet T cell, enter 10°C.
3-11
9. In the HTC cell, enter 0.4.

Since the cost information for the utility is unknown, use the default
value displayed. ExchangerNet requires cost information for each
utility to perform the cost target calculations.
10. Verify that the information on the Utility Streams page appears
similar to the figure below.
Figure 3.8
11. On the Data tab, select the Economics page.
Figure 3.9
ExchangerNet supplies a default set of economic parameters. At least

one set of economic data must be available for the calculation of the
capital cost targets and network capital costs. For this tutorial, leave
the default values as they are.
3-12
3.3 Generating HEN Designs

In this section you will use ExchangerNet’s Recommend Designs feature
to automatically generate HEN designs. ExchangerNet lets you control
how many designs are generated. You can then compare the designs
and make any modifications required.
1. In the Viewer group, click on the Scenario level.
2. Right-click the mouse button on the selected Scenario. The
following menu appears.
Figure 3.10
3. From this menu, select Recommend Designs. The Recommend

Designs view appears as shown in the figure below. This view allows
you to control certain aspects of the automatic design feature.
Figure 3.11
4. On the General tab, in the Stream Split Options group, you can
set the maximum number of branch splits. Accept the current
default values.
5. In the Preview Input group, you can preview any of the input
values for the process streams, utility streams, economics or
forbidden matches. For this tutorial, leave all current default values
as they are.
3-13
3-14 Generating HEN Designs
6. In the Solver Options group, change the maximum number of

ExchangerNet is capable
of solving for more than
designs to 5.
five designs, however, the 7. Click the Solve button. ExchangerNet will begin automatically
time required for the
calculations increases with
creating heat exchanger networks. Depending on the speed of your
the number of designs. system, this could take up to ten minutes to complete.
For learning purposes, five
will be sufficient. If you
have time and want to All generated designs will have a name that starts with “A_”,
calculate more, change indicating that these have been automatically generated by
the maximum design ExchangerNet.
value to the necessary
number.
8. At the Scenario level, click the Designs tab, then check the
Relative to target checkbox. This will show all the key variables as
a percentage of the calculated target value. The view should appear
similar to the figure below. ExchangerNet sorts the results by Total
Cost Index.
Figure 3.12
From the figure above, some of the designs recommended have total
cost indexes higher than the target values, but area values less than
the target values. This minimal area has been made possible by
exceeding the utility energy targets. In most cases this will be true; to
minimize area you must increase utility consumption, and vice-versa.
From the previous figure, it appears as though A_Design3 has the
smallest total cost index, and A_Design5 has the smallest total area.
9. In the Viewer group, click the design level A_Design3.
Depending on your settings, you may have slightly different

results in the list of recommended designs. For the step
above, click on the design that has the smallest total cost
index.
3-14
10. On the Notes tab, select the Modification Log page. This page
displays all the actions performed by ExchangerNet during the
creation of this network design.
Figure 3.13
All of the designs generated by ExchangerNet are optimal for the given
network structure, however, if you had a design that was not already
minimized for area or cost, you can optimize the design by using the
retrofit options described in Chapter 4 - Heat Exchanger Network
Retrofit.
3-15
3-16 References
3.4 References
1
Shenoy, U.V., Heat Exchanger Network Synthesis: Process Optimization by
Energy and Resource Analysis, Gulf Publishing Company, Houston, USA,
1995.
3-16
Heat Exchanger Network Retrofit 4-1
4 Heat Exchanger
Network Retrofit
4.1 Introduction .................................................................................. 2
4.2 Creating an HI Project for Retrofit................................................. 3

4.2.2 Creating the HI Project ............................................................. 4
4.2.3 Entering the Process Stream Data .............................................. 5
4.2.4 Entering Utility Stream Data ...................................................... 9
4.2.5 Building the Heat Exchanger Network ........................................11
4.3 Performing the Retrofit.................................................................18

4.3.1 Entering the Retrofit Environment .............................................18
4.3.2 HEN Retrofit - Resequencing Heat Exchangers.............................19
4.3.3 HEN Retrofit - Repiping Heat Exchangers....................................22
4.3.4 HEN Retrofit - Adding Heat Exchangers ......................................23
4.4 Comparing Designs.......................................................................25
4-1
4-2 Introduction
4.1 Introduction
If you are a new user to In this tutorial, you will use the Automatic Retrofit feature of
ExchangerNet, it is highly
ExchangerNet. You will start by creating a heat exchanger network
recommended that you
complete the HI Case (HEN) in the HI Project environment. Then, you will enter the Automatic
tutorial (refer to Chapter Retrofit environment to retrofit the HEN. During the retrofit, you will
1 - Crude Pre-Heat
Train Network) and HI use four methods:
Project tutorial (refer to • modifying utility exchangers
Chapter 3 - Automatic
HEN Design in HI • resequencing heat exchangers
Project) before starting • repiping heat exchangers
this tutorial.
• adding heat exchangers
It is assumed that you
know how to add and
HEN retrofit focuses on modifying an existing heat exchanger network
complete heat exchangers
on the Grid Diagram. to improve energy efficiency. In the past, HEN retrofits using Pinch
technology required an expert user, and the Mathematical programming
method reduced the interaction between the design engineer and
ExchangerNet. ExchangerNet performs the HEN Retrofit algorithm one
step at a time so the engineer may still control the decision making
process.
The design engineer can apply constraints during the design process
that will affect the retrofit calculations. Within the retrofit environment,
the design engineer is required to choose one type of modification at a
time. The design engineer also has to assess the operational safety and
practicality of the optimal designs generated by ExchangerNet.
4-2
4.2 Creating an HI Project for

Retrofit
The following sections describe how to create a HEN design within the
HI Project environment.

Before you begin, verify that the units currently selected in the session
preferences are the ones you want to use. For this tutorial, the
temperatures are in degrees Celsius, and the MCp is in kJ/°C-s.
1. Open ExchangerNet if it is not already open.
2. From the Tools menu, select Preferences. The Session
Preferences view appears.
3. Click the Variables tab, then select the Units page.
4. In the Available Unit Sets group, select the unit set SI.
The default energy units appear in the units of kJ/h, so, you will
need to define a new unit set.
5. With the unit set SI selected, click the Clone button.
This will create a cloned unit set named New User.
6. In the Unit Set Name field, rename the New User set to
Application 3 Units.
7. In the Display Units group, scroll down the list to find the Energy
units cell. The default unit is kJ/h.
8. In the Energy units cell, click the down arrow. A drop-down list
appears containing various unit options as shown in the figure
below.
Figure 4.1
4-3
4-4 Creating an HI Project for Retrofit
9. From the drop-down list, select kJ/s.

10. In the Display Units group, scroll to the MCp cell.
11. In the MCp cell, click the drop down list and select kJ/C-s.
The unit kJ/s is equal to 12. Scroll through the rest of the list and change the units for the
kW, so in some cases you
can choose which units
following variables:
you want to see displayed. • Ht Tran Coeff (kJ/s-m2-C)
• Heat Flux (kJ/s-m2)
• Fouling (C-m2/kW)
• Enthalpy per Length (kJ/s-m)
• Power (kJ/s)
Although some of these variables might not be used, it is always a good

idea to keep all of the units consistent.
13. Optional: At this point you can save the newly created preference
set, which will allow you to use it in future cases.
To save, click the Save Preference Set icon. On the Save
Preference File view, enter a file name and location, then click the
Save Preference Set icon
Save button.
Although you can
overwrite the default
preference set included
with ExchangerNet, it is
4.2.2 Creating the HI Project
not recommended.
Now you will create the Heat Integration (HI) Project in ExchangerNet.
To access the HI Project view, do one of the following:

• From the Features menu, select HI Project.
• Click the Heat Integration Manager icon, or, from the
Managers menu, select Heat Integration Manager. The
manager view appears. In the left list, select HI Project, then
click the Add button.
icon
4-4
The HI Project view appears.
Figure 4.2
You should
be at the
Scenario
level in the
Viewer
group.
In the
Worksheet
pane, you
should be on
the Process
Streams
page of the
Data tab
4.2.3 Entering the Process Stream

Data
In this section, you will enter data for the process streams on the
Process Stream page on the Data tab.
1. In the Name column, click on **New**.
2. Type H1, then press the ENTER key. The cursor automatically moves
to the Inlet T cell.
3. In the Inlet T cell, enter 347.3°C. The default units that appear in
the unit drop-down list are already in degrees Celsius, so they do
not need to be changed.
If you know the temperature in a unit other than the default, type
the known temperature in the cell, then select the appropriate units
from the drop-down list, as shown in the figure below.
4-5
ExchangerNet automatically converts the value to the default units.

For example, if you enter 113°F, ExchangerNet converts this value
to 45°C.
Figure 4.3
5. In the MCp cell, enter 180.1 kJ/°C-s.
After you enter the inlet and outlet temperatures, ExchangerNet knows
if the stream type is hot or cold. A red or blue arrow appears in the
second column. A red arrow indicates a hot stream; a blue arrow
indicates a cold stream.
Next, you will segment this stream and add other streams to the HI
Project.
Segmenting Process Streams

The H1 stream requires an enthalpy or heat capacity value to be
complete. All other information is optional. When you enter this
information, ExchangerNet generates a default heat transfer coefficient
Double-click in the HTC value for the HTC cell. For this tutorial, you will use the default
column to open the HTC
Default Values view,
coefficient values generated by ExchangerNet.
which contains a list of
default heat transfer In this section you will add streams and segment some of the streams.
coefficients for various
materials. Accept the
Stream segmentation is extremely useful for streams that change
default value or select a phase or have non-linear variations in enthalpy as the temperature
new default value. changes.
1. In the H1 stream row, double-click on any cell (except HTC) to open
4-6
the Process Stream view.
Figure 4.4
2. Click once in the Outlet T cell containing the value 45.0. This is the
target outlet temperature.
The blank segment row 3. Click the Insert Segment button. A blank row appears above the
always appears above the target outlet temperature.
row containing the cursor.
4. The outlet temperature of the first segment is 202.7°C.
Click in the empty Outlet T cell and enter 202.7.
ExchangerNet automatically inserts the inlet temperature for the
following segment.
5. The MCp for the first segment is 217.3 kJ/°C-s.
Click in the empty MCp cell and enter 217.3.
The process stream is complete as shown in the figure below.
Figure 4.5
6. Click the Close icon to return to the Data tab of the HI Project
view.
Close icon
4-7
7. Now that you know how to successfully enter process stream

information and create segmented streams, enter the following
stream information.
Enter the stream name, first Inlet T value and the target
(last) Outlet T value on the Process Streams tab before
accessing the Process Stream view to enter the segment
information.
Enter only the Outlet T values and the MCp values; the Inlet T
values are calculated for you.
Stream MCp (kJ/°C-

Inlet T (°C) Outlet T (°C)
Name s)
H2 319.4 244.1 136.2
H3 297.4 203.2 22.08
203.2 110.0 19.76
H4 263.5 180.2 123.1
H5 248.0 143.7 67.41
143.7 50.0 58.11
H6 231.8 176.0 51.14
176.0 120.0 46.49
H7 167.1 116.1 172.0
116.1 69.6 158.1
H8 146.7 133.3 233.6
133.3 120.0 202.2
120.0 99.9 169.7
99.9 73.2 338.2
H9 73.2 30.0 6.843
H10 73.2 40.0 57.69
C11 232.2 274.3 471.9
274.3 343.3 498.6
C12 30.0 108.1 333.6
108.1 211.3 381.2
211.3 232.2 481.2
C13 226.2 228.7 352.2
228.7 231.8 425.4
4-8
8. Verify that the information on the Process Streams page appears

similar to the following figure.
Figure 4.6

In this section, you will specify all the required heating and cooling
utilities for the HEN design.
1. Click on the Data tab, then click on the Utility Streams page.
The hot and cold status bars at the bottom of the tab
displays “insufficient”, which means that there are not
enough cold and hot utilities to satisfy the process streams.
2. In the Name Column, click on <empty>. A drop-down arrow

becomes active.
Figure 4.7
3. Click the arrow, and a drop-down list appears containing all of the
default utilities available within ExchangerNet.
Figure 4.8
4-9
4. Select the following default utilities from the list:

• Cooling Water
You can change or define • Fired Heat (1000) - If a warning box appears, click OK.
economics parameters
on the Economics page • HP Steam
of the Data tab. Refer to • LP Steam Generation
step #6.
• MP Steam
• MP Steam Generation
5. Verify that the information on the Utility Streams page appears
similar to the figure below.
Figure 4.9
6. On the Data tab, click on the Economics page.
Figure 4.10
ExchangerNet supplies a default set of economic parameters for a

typical heat exchanger. Here, you can change or add another type of
installation cost and area-related cost law coefficient if required. At
least one set of economic data must be available for the calculation of
the capital cost targets and network capital costs.
For this tutorial, you will use the default values.
4-10
4.2.5 Building the Heat Exchanger

Network
In this tutorial, you will add heat exchangers only to the heat
exchanger network. Splitters are not required.
Accessing the Design Level

To build the HEN diagram, you must enter the Design level of the HI
Project view.
1. In the Viewer group, click on the + beside Scenario 1 to expand
the tree.
2. Click on the design named Design 1. The view appears as shown in
the figure below.
Figure 4.11
The Main
pane
displays the
Grid
Diagram
instead of
the plots.
The status
bar is not
green. There
are 13
unsatisfied
streams.
4-11
Setting the Grid Diagram View Options

To modify the appearance of the heat exchanger network design in the
Grid Diagram:
1. Open the Property Presets view by doing one of the following:
• Click the Open Palette View icon. The Design Tools palette
appears.Click the Open Property Preset View icon.
Figure 4.12
Open Property Preset

View icon
• Right-click on the Grid Diagram, then select Properties from

the Object Inspect menu.
2. The Property Presets view appears.
Select Preset 4: (Temperature), then click the Edit button.
The Property Preset: Preset 4: (Temperature) view appears.
4. In the Heat Exchangers group, click the Middle drop-down list.
5. From the drop-down list, select Name.
The stream name will now appear in the Grid Diagram.
6. Close both the Property Presets and Property Preset: Preset 4:
(Temperature) views to return to the HI Project view.
4-12
Adding Heaters
In this section, you will add heat exchangers to the network design.
The Design Tools palette must be visible before you can add heat
exchangers.
1. Press F4 to open/access the Design Tools palette.
Exchanger icon.
3. Drag the cursor over the C11 stream until the Bull’s eye icon
appears.
4. Release the mouse button. The heat exchanger appears as a solid
red dot.
5. To attach the heat exchanger to the Fired Heat (1000) stream, click
and hold on the red dot, then drag the cursor to the Fired Heat
stream. A light blue dot will appear underneath the cursor as you
Bull’s eye icon
drag it to the new stream.
6. Release the mouse button. The heat exchanger appears. Since this
is a heater, the heat exchanger is red.
Red dot icon 7. Double-click either end of the heat exchanger (the red dots) to open
the Heat Exchanger property view.
Light blue dot icon 9. In the Name field, enter HU1.
(under four arrows)
11. On the Data tab, Click the Tied checkbox for the C11 cold stream
outlet temperature. The heat exchanger property view appears as
Figure 4.13
C11 is a cold stream
C11 stream Outlet C11 stream Inlet

Temperature Temperature
Fired Heat (1000)

stream Outlet
Temperature
Fired Heat (1000) stream Fired Heat (1000)

Inlet Temperature is a hot stream
4-13
12. In the Duty field, enter 37.9, then select MW from the units list.
Since the C11 stream is
being heated to the
known outlet Figure 4.14
temperature, you can
“tie” the cold stream
outlet temperature value
to the outlet temperature
value previously entered
on the Process Streams
tab.
The heat exchanger solves, and the view appears as shown in the figure
below.
Figure 4.15
13. Use the procedure you just learned and the data in the table below
to add the other heaters.
When placing heat exchangers on the stream, remember

that the hot streams flow from left to right, while the cold
streams flow from right to left.
4-14
Cold Stream
Location of Heat (°C) Duty
Name Streams
Exchanger Inlet Outlet (MW)
T T
HU2 C12 & HP Place on C12 Tied 27.8
Steam stream
HU3 C13 & HP Place on C13 Tied Tied
Steam stream
“Tied” indicates that you must check the Tied checkbox as indicated. A
blank cell in the table above indicates that ExchangerNet will calculate
the value.
Adding Heat Exchangers

In this section, you will add heat exchangers to the Grid Diagram.
1. Press F4 to open/access the Design Tools palette.
Exchanger icon.
3. Drag the cursor over the H6 stream until the Bull’s eye icon
Add Heat Exchanger icon appears.
4. Release the mouse button. The heat exchanger appears as a solid
red dot.
5. To attach the heat exchanger to the C12 stream, click and hold on
the red dot, then drag the cursor to the C12 stream. A light blue dot
Bull’s eye icon will appear underneath the cursor as you drag it to the new stream.
Remember that cold streams flow from right to left. Place

the new heat exchanger upstream from (to the right of) HU2
Red dot icon on the C12 stream.
Figure 4.16
Light blue dot underneath

four arrow cursor
7. Double-click either end of the heat exchanger (the gray dots) to

open the Heat Exchanger property view.
4-15

9. In the Name field, enter E1.
You know from the stream 10. Click the Data tab.
information you entered
on the Process Streams 11. Click the Tied checkbox for the inlet hot stream temperature.
tab that the inlet hot
stream temperature for E1 12. Click the Tied checkbox for the outlet cold stream temperature.
is the same as the initial 13. In the Duty field, enter 0.7 MW. The heat exchanger solves.
stream temperature for
H6. 14. Use the procedure you just learned and the data in the table below
to add the rest of the heat exchangers and coolers to the Grid
If you make an error and
need to delete a heat Diagram.
exchanger, right-click
either end of the
exchanger and select When placing heat exchangers on the stream, remember
Delete from the Object that the hot streams flow from left to right, while the cold
Inspect menu. streams flow from right to left. This is important when
placing heat exchangers ‘before’ or ‘after’ other exchangers
in the design.
“Tied” indicates that you must check the stream Tied checkbox. A blank
cell indicates that ExchangerNet will solve the value.
Hot Stream Cold Stream

(°C) (°C) Load/
Location of Heat
Name Streams Duty
Exchanger Inlet Outlet Inlet Outlet (MW)
T T T T
E2 H1 & C11 Place on C11 stream, Tied Tied 15.2
before HU1
E3 H3 & C11 Place on C11 stream, Tied Tied Tied
before E2
E4 H3 & C12 Place on H3 stream, after Tied Tied 0.7
E3
Place on C12 stream,
before E1
E5 H1 & C12 Place on H1 stream, after Tied Tied Tied
E2
before E4
E6 H3 & C12 Place on H3 stream, after Tied Tied Tied
E4
before E5
CU1 H3 & Place on H3 stream, after Tied Tied
Cooling E6
Water
CU2 H6 & Place on H6 stream, after Tied Tied
Cooling E1
Water
CU3 H10 & Place on H10 stream Tied Tied
Cooling
Water
Cooling
Water
4-16
Hot Stream Cold Stream

(°C) (°C) Load/
Location of Heat
Name Streams Duty
Exchanger Inlet Outlet Inlet Outlet (MW)
T T T T
Cooling
Water
Cooling
Water
Cooling
Water
CU8 H2 & MP Place on H2 stream Tied Tied
Steam
Generatio
n
CU9 H4 & LP Place on H4 stream Tied Tied
Steam
Generatio
n
After entering the information in the table above, the Grid Diagram
should appear as shown in the figure below. There might be some
variation in the heater placement.
Figure 4.17
4-17
4-18 Performing the Retrofit
4.3 Performing the Retrofit

4.3.1 Entering the Retrofit
Environment
In this section, you will use ExchangerNet’s retrofit tools to generate
optimal HEN designs.
1. In the Viewer group, select Scenario 1.
2. Click the Enter Retrofit Mode icon located at the bottom right
corner of the view.
Enter Retrofit Mode icon
3. The Enter Retrofit Environment view appears, as shown in the figure
below.
Figure 4.18
Ensure the
Create New
Retrofit Scenario
is selected.
Read the
suggestions on
the Tips tab to
Select the design
simplify the
to be entered into
design before
the Retrofit
entering into the
Environment.
HEN Retrofit
environment.
While you are in the Retrofit Mode you cannot make any
changes to the design and stream information.
The Tips tab contains the following information:

• Reduce the scope of the problem by minimizing the number of
streams and heat exchangers in the heat exchanger network.
Remove the exchanger(s) at either end of the streams that you
don't want to modify and update the corresponding inlet or
outlet stream temperatures. This can simplify the network and
increase the efficiency of the model.
• Keep stream segmentation to a minimum as they increase the
computational power required to solve the problem.
• Combine adjacent heat exchangers between two process
streams into one heat exchange when possible. This has no
effect in the final outcome but makes the solver work more
efficiently.
4-18
• Remove all energy streams. Energy streams are important to

establish the targets of a process but are not necessary to
perform a retrofit study. By removing them, the problem
becomes easier to solve.
Verify that the heat exchanger network represented in

ExchangerNet matches the setup that exists in the plant
before entering the retrofit environment. This will ensure
that accurate and meaningful designs are generated when
retrofit is performed.
4. Click the Enter Retrofit Environment button.

The following view appears (Performance tab, Summary page).
Figure 4.19
ExchangerNet
creates a new
scenario called
Scenario 1 1.
The light blue
folders indicate
you are in the
Retrofit
environment.
4.3.2 HEN Retrofit - Resequencing

Heat Exchangers
In this section you will generate a retrofit design by resequencing the
heat exchangers.
1. In the Viewer group, select Design 1 under Scenario 1 1 (blue
4-19
folder).
2. Click the Open Palette View icon. The Design Tools palette
appears.
3. On the Design Tools palette, click the Modify utility heat
exchanger icon.
In this example, it is not optimal to modify any of the utility heat
exchangers. The following view appears.
Modify utility heat
exchanger icon
Figure 4.20
4. Click the OK button to close the view. The view for Scenario 1 1
appears.
folder) again.
appears.
7. On the Design Tools palette, click the Move one end of a Heat
Exchanger icon. The Retrofit Specifications view appears.
Move one end of a Heat Figure 4.21

Exchanger icon
8. In the Maximum Investment field, enter a capital cost investment

value. Entering a value here helps ensure that ExchangerNet will
generate retrofit solutions. Leave the field as the default if you want
to see if ExchangerNet can generate a solution requiring no capital
investment.
9. Click the Run button. ExchangerNet begins retrofit calculations.
The following view will appear if ExchangerNet calculates a cost
above what you entered in the previous step.
Figure 4.22
4-20
To display the exchanger

In this view, you can do the following:
names in the new design, •Click Delete Design to exit the calculation and delete the
refer to the previous design.
Setting the Grid
Diagram View Options • Click Keep Design to finish the calculation and keep the design.
section. • Click Recalculate and enter a new Maximum Investment value.
10. For this tutorial, click Keep Design.
A new design called Design 1-1S appears in the Viewer group.
11. In the Viewer group, select Design 1-1S. Verify that the Grid
Diagram appears similar to the view below.
Figure 4.23
The green icon

indicates that a
section of the
heat exchanger
has been moved.
4-21
4.3.3 HEN Retrofit - Repiping Heat

Exchangers
folder).
appears.
3. On the Design Tools palette, click the Move both ends of a Heat
Exchanger icon. The Retrofit Specifications view appears.
Figure 4.24
Move both ends of a Heat
Exchanger icon

investment.
Figure 4.25

• Click Delete Design to exit the calculation and delete the
design.
• Click Keep Design to finish the calculation and keep the design.
• Click Recalculate and enter a new Maximum Investment value.
To display the exchanger 6. For this tutorial, click Keep Design.
names in the new design,
refer to the previous
A new design called Design 1-1P appears in the Viewer group.
Setting the Grid
Diagram View Options
section.
4-22
7. In the Viewer group, select Design 1-1P. Verify that the Grid
Figure 4.26
The two green

icons indicate
that the heat
exchanger has
been moved.
8. From the status bar in Figure 4.26, it can be seen that Design 1-
1P has one infeasible heat exchanger. As a result, this design is
incomplete.
4.3.4 HEN Retrofit - Adding Heat

Exchangers
1. In the Viewer group, select Design 1 under Scenario 1 1.
appears.
Open Palette View icon 3. On the Design Tools palette, click the Add a Heat Exchanger icon.
The Retrofit Specifications view appears.
Figure 4.27
4-23

investment.
Figure 4.28

• Click Delete Design to exit the calculation and delete the
design.
• Click Keep Design to finish the calculation and keep the design.
• Click Recalculate and enter a new Maximum Investment value.
To display the exchanger 6. For this tutorial, click Keep Design.
names in the new design,
refer to the previous A new design called Design 1-1N appears in the Viewer group.
Setting the Grid 7. In the Viewer group, select Design 1-1N. Verify that the Grid
Diagram View Options
Figure 4.29
The two green

icons and a new
exchanger name
indicate that the
heat exchanger
was added.
4-24
4.4 Comparing Designs

Now that ExchangerNet has generated two possible design
improvements, you can compare each design and decide which one
best suits the project requirements.
1. In the Viewer group, select Scenario 1 1.
2. Click the Designs tab. The following worksheet appears. The values
displayed may be different from what appears below.
Figure 4.30
The Designs worksheet displays data on the original and all the retrofit
generated designs. For each retrofit generated design you can compare
the following:
• the payback of the generated design
• new area required
• capital investment required
• energy consumption reduction
• operation costs reduction
Remember that all estimated cost values are based on the

ExchangerNet default economic parameters. You can change the
economic parameters on the Economics page of the Data tab. All
modification changes are compared to the base case design.
4-25
4-26 Comparing Designs
3. Click the checkbox beside Relative to base design to view the

above data with percent values relative to the original HEN design.
Figure 4.31
4-26

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Conceptual Process

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Honeywell International Sàrl

2 Data Extraction from UniSim Design..................... 2-1

3 Automatic HEN Design in HI Project ..................... 3-1

4 Heat Exchanger Network Retrofit ......................... 4-1

1 Crude Pre-Heat Train

1.2 Entering Process Information ........................................................ 4

1.3 Examining the Targets ..................................................................12

1.4 Building the Heat Exchanger Network ..........................................15

Crude oil is often fractionated to produce saleable products such as

Effluent leaving the desalter is heated up further in heat exchangers 9,

Figure 1.1: Process Flowsheet

1.2 Entering Process

1.2.1 Setting Unit Preferences

7. Click the Close icon to close the Session Preferences view.

1.2.2 Creating an HI Case

Now, you can create the Heat Integration (HI) Case.

To access the main HI Case view, do one of the following.

1.2.3 Entering Process Stream

Segmenting Process Streams

2. To add a segment, click in the target outlet temperature cell (90°C)

7. To view the temperature versus enthalpy plot, click on the Graphs

Now that you know how to successfully enter process stream

Stream Heat Load/Enthalpy

1.2.4 Entering Utility Stream Data

3. Click the down arrow to open the drop-down list.

5. Repeat steps #2 - #4 to add the following utilities:

The Hot status bar now displays a sufficient status.

All utilities have default costs associated with them. This

6. Click the Economics tab.

A default set of economic parameters is supplied by

1.3 Examining the Targets

To open the Targets view:

The minimum number of units required to build this heat exchanger

1.3.1 Range Targeting

Click on the View After the calculations are

4. To find a better approximation of the optimal DTmin value, you need

9. Click the Calculate button. ExchangerNet automatically closes the

10. To verify this value, click on the Table page.

1.4 Building the Heat

1.4.2 Modifying HEN Diagram

4. Click the Annotations tab.

5. In the Heat Exchangers group, click the Middle drop-down list

6. Click the Close icon to close the Property Preset 4:(Temperature)

1.4.3 Adding a Splitter

Add Split icon

Bull’s eye icon

2. Right-click and hold on the Add Split icon.

Each segment of the split is called a branch.

1.4.4 Adding Heat Exchangers

The streams on the Grid Diagram appear dashed because the

Light blue dot icon

ExchangerNet may appear to move the heat exchanger to the bottom

Hot Stream Hot Stream

The Desalter Feed stream passes through the hottest part of

Add Heat Exchanger icon

5. Release the mouse button. The heat exchanger appears.

6. Double-click on either end of the heat exchanger (the grey circles)