Pinch Analysis:

Concepts

Prof. G.P. Rangaiah

Department of Chemical & Biomolecular
Engineering @ NUS

Dr. GP Rangaiah
 Pinch Analysis Concepts - Outline

 Overview
 Energy Balance
 Temperature-Enthalpy Diagram
 Composite Curves
 Problem Table Procedure
 Pinch and its Significance
 Grand Composite Curves
 Heat Exchanger Network
o Grid Representation
o Design for Maximum Energy Recovery
 Examples/Practice Session
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 Overview

 What is Pinch Analysis

 A Set of Procedures for Heat Integration
• Simple, Based on Fundamental Principles, Systematic

 Provides Targets and Heat Exchanger Networks

 Developed since 1970’s onwards at ETH and Leeds

University by Bodo Linnhoff and co-workers

 Extended to Other Areas

• Wastewater Minimization, H2 Management

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 Example

 Process Flowsheet
20oC 135oC
Heater
2 kW/oC

80oC 140oC
Heater Reactor
o
4 kW/ C
 Stream Data 3 kW/oC 170oC

Cooler
Stream CP Supply Target
No. & (kW/K) (Initial) (Final)
60oC
Type TS (oC) TT (oC)
30oC 150oC
(1) Cold 2.0 20 135 Cooler Separator
1.5 kW/ oC
(2) Hot 3.0 170 60
(3) Cold 4.0 80 140
(4) Hot 1.5 150 30

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 Energy Balance

 Enthalpy Changes
Stream CP Supply Target Enthalpy Change
No. & (kW/K) (Initial) T, (Final) T, (Heat Load)
Type TS (oC) TT (oC) (kW)
(1) Cold 2.0 20 135 2(20 – 135) = – 230
(2) Hot 3.0 170 60 3(170 – 60) = + 330
(3) Cold 4.0 80 140 4(80 – 140) = – 240
(4) Hot 1.5 150 30 1.5(150-30) = + 180

 Energy Balance
Net Heat Load = 330 + 180 – 230 – 240 = + 40 kW
Remove or Supply using a Cold or Hot Utility?
Feasible?
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 Temperature-Enthalpy Diagram
 Simple Example with 2 Process Streams
Stream Mass Specific Heat CP Supply T, Target T, Heat Load,
Type Flowrate Capacity, CP (kW/K) TS (oC) TT (oC) H (kW)
(kJ/kg.K)
Cold 0.25 4 1.0 20 200 - 180
Hot 0.4 4.5 1.8 150 50 + 180

Process
With Heat
Exchange

How much energy can be recovered?

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 Temperature-Enthalpy Diagram
Heat Load or Enthalpy Change when a Process
Stream changes from Supply to Target Temperature
Q = H = CP (TS - TT)
assuming Constant Specific Heat

T/H Diagram for

Two Process Streams

Heat Recovery depends

on Minimum Temperature
Difference - How to find?

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 Composite Curves

 More than One Hot/Cold Stream

Stream CP TS TT Enthalpy
(kW/K) (oC) (oC) Change
(kW)
(2) Hot 3.0 170 60 + 330
(4) Hot 1.5 150 30 + 180

How to represent
2 hot streams
on a T/H Diagram?

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 Composite Curves

 More than One Hot Stream – Hot CC

Stream CP TS TT Enthalpy
(kW/K) (oC) (oC) Change
180
(kW) 170
160
(2) Hot 3.0 170 60 + 330 150
140
130
(4) Hot 1.5 150 30 + 180

Temperature (oC)
120
110
100
90
80
Temperature CP Enthalpy 70
60
Range (kW/K) Change (kW) 50
40
170 to 150 3.0 60 30
20
150 to 60 3.0 + 1.5 405 10
0
60 to 30 1.5 45 0 50 100 150 200 250 300 350 400 450 500 550 600
Heat Flow (kW)

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 Composite Curves

 More than One Cold Stream – Cold CC

Stream CP TS TT Enthalpy
(kW/K) (oC) (oC) Change 180
(kW) 170
160
(1) Cold 2.0 20 135 - 230 150
140
130
(3) Cold 4.0 80 140 - 240

Temperature (oC)
120
110
100
90
Temperature CP Enthalpy 80
70
Range (kW/K) Change (kW) 60
50
20 to 80 2.0 - 120 40
30
80 to 135 2.0 + 4.0 - 330 20
10
135 to 140 4.0 - 20 0
0 50 100 150 200 250 300 350 400 450 500 550 600
Heat Flow (kW)

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 Composite Curves

 Cold and Hot Composite Curves

Heating
Duty

(T)min

Heat Recovery
Region

Cooling
Duty

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 Composite Curves
Targets from Heating
Duty =
Composite 20 kW
Curves

Tmin =
Tmin = 10oC 10oC

Hot Utility
= 20 kW Heat Recovery = 450 kW

Cold Utility
= 60 kW
Cooling
Duty =
60 kW
Pinch at
85 (or 90/80) oC
Dr. GP Rangaiah 12
 Pinch and its Significance
Pinch Point: Driving force = Tmin
Red Dotted Region
Energy given by hot
streams from 170oC
Tmin = to pinch temperature
10oC (330 kW) + Hot
Blue Dotted Region Utility (20 kW) =
Energy required by
Energy given by hot
cold streams from
streams from pinch
pinch temperature to
temperature to 30oC
140oC (350 kW)
(180 kW) = Energy
required by cold
Red dotted region is
streams from 20oC
to pinch temperature in energy balance.
(120 kW) + Cold
Utility (60 kW)

Blue dotted region is Conclusion: there is NO heat flow across

in energy balance. (i.e., from above to below) the pinch point.
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 Problem Table Procedure

 Stream Temperature & Shifted Temperature

Stream No. CP TS TT
& Type (kW/K) (oC) (oC) Tmin = 10oC
(1) Cold 2.0 20 135
Stream T with
Shifted T in
(2) Hot 3.0 170 60
Brackets
(3) Cold 4.0 80 140
(4) Hot 1.5 150 30
Stream No. TS (oC) TT (oC)
& Type

(1) Cold 20 135

Shifted
(25) (140)
Temperature, T (2) Hot 170 60
(165) (55)
= Th - (½)Tmin
(3) Cold 80 140
= Tc + (½)Tmin (85) (145)
(4) Hot 150 30
(145) (25)

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 Problem Table Procedure

 Streams and Temperature Intervals

Stream CP TS TT (oC)
No./Type (kW/K) (oC)
(1) Cold 2.0 20 135
(25) (140)
(2) Hot 3.0 170 60
(165) (55)
(3) Cold 4.0 80 140
(85) (145)
(4) Hot 1.5 150 30
(145) (25)

Tmin = 10oC

Shifted T
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 Problem Table Procedure
Stream CP
 Problem Table No. (kW/K)
(1) Cold 2.0
Shifted Interval Si - Si+1 CPhot - CPcold H Surplus
(2) Hot 3.0
T, Si (oC) No., i (oC) (kW/oC) (kW) or Deficit
(3) Cold 4.0
S1 = 165 (4) Hot 1.5
1 20 + 3.0 + 60 S
S2 = 145 How to take
2 5 + 0.5 + 2.5 S care of
S and D?
S3 = 140
3 55 - 1.5 - 82.5 D
S4 = 85
4 30 + 2.5 + 75 S
S5 = 55
5 30 - 0.5 - 15 D
S6 = 25

Dr. GP Rangaiah 16
 Problem Table Procedure
Heat Cascade
Feasible

Negative Hot Utility = 20 kW

Heat Cold Utility = 60 kW
Cascade
Pinch at
Infeasible Heat Cascade = 0

Pinch Temperature:
85 (or 90/80) oC

Dr. GP Rangaiah 17
 Problem Table Procedure
 Problem Table including Heat Cascade
Shifted T, Interval Si - Si+1 CPhot - H Surplus Infeasible Feasible
Si (oC) No., i (oC) CPcold (kW/oC) (kW) or Deficit Cascade Cascade
S1 = 165 0 20
1 20 + 3.0 + 60 S
S2 = 145 60 80
2 5 + 0.5 + 2.5 S
S3 = 140 62.5 82.5
3 55 - 1.5 - 82.5 D
S4 = 85 - 20 0
4 30 + 2.5 + 75 S
S5 = 55 55 75
5 30 - 0.5 - 15 D
S6 = 25 40 60

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 Grand Composite Curve
Heating
Duty =
 Plot of Shifted 20 kW

Temperature versus
Net Heat Flow (Heat
Cascade)
Pinch

 Net Heat Sink

Shifted T
= 85oC

 Net Heat Source

Cooling Duty


= 60 kW
Useful for Choosing
Utility Level and
Quantity

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 Pinch and its Significance

 Pinch
 Driving force is minimum
 Divides the problem
•Above Pinch
•Below Pinch

 Net Heat Sink

•Above Pinch
 Net Heat Source
•Below Pinch

Dr. GP Rangaiah 20
 Pinch and its Significance
+ 10
kW

+ 10
kW
Flow
+ 10
kW
 Golden Rules
 NO heat transfer across the pinch
 NO cold utilities above the pinch
 NO hot utilities below the pinch
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 Pinch and its Significance

 Simple and Effective Concepts

 Targets
 Pinch Point
 More In, More Out
 Flexibility: Problem Division
 Trade-offs
•Energy Targets and Number of Exchangers

Dr. GP Rangaiah 22
 Example

 Process Flowsheet 20oC

Heater
135oC

 Stream Data 2 kW/oC

80oC 140oC
Stream CP Supply Target Heater Reactor
o
No. & (kW/K) (Initial) (Final) 4 kW/ C
Type TS (oC) TT (oC) 3 kW/oC 170oC
(1) Cold 2.0 20 135
Cooler
(2) Hot 3.0 170 60
(3) Cold 4.0 80 140 60oC
30oC 150oC
(4) Hot 1.5 150 30 Cooler Separator
1.5 kW/ oC

 Targets Found Tmin = 10oC

Will be used in
Hot Utility = 20 kW, Cold Utility = 60 kW Heat Exchanger
Pinch Temperature: 85oC (or 90/80oC) Network Design

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 Heat Exchanger Network

 Grid Representation of HEN

Initial Grid Diagram for the Four-stream Problem

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 Heat Exchanger Network
Grid
 Commonsense Network Design Representation
Step 1: Heat of HEN
Exchange
between S2 & S3
Step 0:
Useful
90
1 Quantities

110
2
180

1
240 Next
Step 2: Heat Step?
Exchange
Dr. GP Rangaiah
between S4 & S1
25
 Heat Exchanger Network
Grid
 Commonsense Network Design Representation
Step 1: Heat of HEN
Exchange Step 4:
between S2 & S3 Cooler
Step 0:
Useful
90
1 C Quantities
90

110
H 2
50 180

1
240
Step 3: Compare with
Step 2: Heat
Heater Min. HU = 20 kW
Exchange
between S4 & S1 Min. CU = 60 kW
Dr. GP Rangaiah 26
 Heat Exchanger Network

 Design for Maximum Energy Recovery (MER)

 Minimum Utilities
 Pinch and its Significance
 Golden Rules

 Pinch Point
 Design Above Pinch
 Design Below Pinch

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 Heat Exchanger Network

 Above Pinch
o No Cold Utilities
o Hot streams have to be cooled to the pinch point using
cold streams only

 Below Pinch
o No Hot Utilities
o Cold streams have to be heated to the pinch point using
Hot streams only

Start Network Design

at the Pinch (Most Constrained Point)
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 Heat Exchanger Network
 Design for Maximum Energy Recovery

Feasibility of a pinch match

Feasibility of a pinch match
above pinch requires:
below pinch requires:
CPHot ≤ CPCold
CPHot ≥ CPCold

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 Heat Exchanger Network

 MER Design for the Example

Start with Grid Place Useful

Quantities:
Diagram
CP and H

CP Pinch at 90/80 H
S. No.
170 90 60
2 3.0 240/90

150 90 30 90/90
4 1.5

135 80 20
1 2.0 110/120

3 4.0 140 80 240/0

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 Heat Exchanger Network

 Design Above Pinch for MER

CP requirement: CPHot ≤ CPCold for a pinch match

Heuristic for Lower Capital Cost of HEN: Maximum Q on each HE

Match Match
2 1
CP Pinch at 90/80 H
S. No.
170 90 60
2 3.0 1 240/90

150 90 30 90/90
4 1.5 2

135 125 80 20
1 2.0 H 2 110/120
20 90
3 4.0 140
1
80 Next: Design 240/0
240
Below Pinch
Heater
Dr. GP Rangaiah 31
 Heat Exchanger Network

 Design Below Pinch for MER

CP requirement: CPHot ≥ CPCold for a pinch match

Heuristic for Lower Capital Cost of HEN: Maximum Q on each HE

Identify
Match Pinch
Pinch at 90/80
3 Match(es)
CP H
S. No.
170 90 60
2 3.0 1 3 240/90
Match 4:
150 90 70 30 90/90
4 1.5 2 4 C OK?
60
135 125 80 35 20
1 2.0 H 2 3 4 110/120
20 90 90 30
3 4.0 140 80 240/0
1
Cooler
240
Dr. GP Rangaiah 32
 Heat Exchanger Network

 Complete HEN for MER

CP Pinch at 90/80 H
S. No.
170 90 60
2 3.0 1 3 240/90

150 90 70 30 90/90
4 1.5 2 4 C
60
135 125 80 35 20
1 2.0 H 2 3 4 110/120
20 90 90 30
3 4.0 140 80 240/0
1
240

Compare with Targets:

Min. HU = 20 kW; Min. CU = 60 kW

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 Heat Exchanger Network
20oC 135oC
Heater
2 kW/oC

80oC 140oC
Heater Reactor
4 kW/oC
3 kW/oC 170oC

Cooler

60oC
o o
30 C 150 C
Cooler Separator
o
1.5 kW/ C
HEN
Designed for
Process 20 35 80 125 135 Minimum
4 3 2 H Utilities
Flowsheet
S1 80 140
with Heaters
1 Reactor
and Coolers S3
S2 170
Process
1
Flowsheet with
HEN Designed for 90
Minimum Utilities 3
S4 60
30 70 90 150
C 4 2 Separator

Dr. GP Rangaiah 34
 Heat Exchanger Network

Process Flowsheet with

90
HEN Designed for Minimum
90
Utilities
20 35 80 125 135
4 3 2 H
S1
70 60 90
80 140
1 Reactor
S3
S2 170

60
20oC
Heater
135oC 30 150
2 kW/oC
C Separator
80oC
Heater
140oC
Reactor
S4
o
4 kW/ C
3 kW/oC 170oC

Cooler

60oC
30oC 150oC
Cooler Separator
1.5 kW/ oC
Dr. GP Rangaiah 35
 Supertargeting

 Choice of Tmin

With increasing Tmin,

Utilities increase and
HE area decreases
[since Q = U A (T)LM]

Optimum Tmin

Dr. GP Rangaiah 36
 Pinch Analysis Concepts - Summary

 Overview
 Energy Balance
 Temperature-Enthalpy Diagram
 Composite Curves
 Problem Table Procedure
 Pinch and its Significance
 Grand Composite Curves
 Heat Exchanger Network
o Grid Representation
o Design for Maximum Energy Recovery
 Examples/Practice Session
Dr. GP Rangaiah 37