Introduction to Pinch Technology

1. Introduction

The demand for effective usage of energy processes is increasing and nowadays every
process engineer is facing the challenge to seek answers to the questions related to their process
energy patterns. Below the questions that frequently may be asked are listed:
 Is the existing process as energy efficient as it should be?
 How can new projects be evaluated with respect to their energy requirements?
 What changes can be made to increase the energy efficiency without incurring any cost?
 What investments can be made to improve energy efficiency?
 What is the most appropriate utility mix for the process?
 How to put energy efficiency and other targets like reducing emissions, increasing plant
capacities, improve product qualities etc, into a one coherent strategic plan for the overall
site?
All these questions and more can be answered with a full understanding of Pinch Technology
and an awareness of the available tools for applying it in a practical way. The aim here is to
provide the basic knowledge of pinch technology concept and how it can be applied across a
wide range of process industries. The pinch technology was proposed firstly for optimization of
heat exchangers and therefore it is introduced / described below for such devises. Heat exchange
equipments encounter in many industries for at least two reasons; a) it is often necessary as part
of the process to change the thermal condition and b) it is the ambition to minimize the energy
consumption of the given process. With other words the idea is to maximize the energy recovery
within the process or to minimize the use of external energy sources. Figs 1 and 2 illustrate this
meaning.

HEX HEX HEX HEX

HEX HEX HEX

HEX HEX HEX

a) b)
Figure 1. a) Process with only external energy sources and b) Process with internal and external
energy sources.

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 In Fig. 1a heat is added or removed only with external sources (heaters and coolers) while the
same process can be improved by using internal heat exchanges under the condition of an overlap
in the temperature intervals, see Fig 1b. The need of external energy sources can be reduced by
using internal heat exchanges between cold and hot streams and a more energy efficient process
can thus be achieved. However, it does not mean that the total cost is reduced since the use of
internal heat exchange results in increased capital cost through bigger or more heat exchanger
units. Fig. 2 shows how heat can be recovered in s simple process scheme by using internal heat
exchange.

Steam

Feed Product
Reactor
1 2
200C
80C 90C

Cold Water
a)
Steam

Feed Product
Reactor
1 2
200C
80C 90C

Cold Water

b)
Figure 2. A simple process a) with external energy sources only and b) with internal and external
energy sources.

The application of such optimization method is referred as “Pinch Technology” that

guarantee minimum energy levels in design of heat exchanger network in a process.

2. Problem Statement

A typical industrial process may consist of several numbers of hot and cold process streams
which may demand cooling and heating respectively. Heat exchangers can be used to recover
some of the heat demand while external heaters and coolers can be used to achieve the
temperature demand of the process streams. Suppose an industrial plant with hot and cold process

3
streams as shown in table 1. Heat capacity rate is defined as mass flow rate times heat capacity

mCp .
Table 1. Process streams in an industrial plant.
Process stream Inlet Temp. Outlet Temp. Heat capacity rate 

Nr / Type [kW/K] Q [kW]

[C] [C]
1. cold 90 420 10 3300
2. cold 170 350 32 5760
3. cold 200 390 29 5510
4. hot 440 140 27 8100
5. hot 510 300 24 5040

The task is to find the optimal network of heat exchangers, external coolers and external
heaters with respect to the capital and annual operating cost. The maximum heat that can be
transferred in a heat exchanger is limited by the minimum allowed temperature difference
between hot and cold streams, called as Tmin. The temperature level at which Tmin is observed
is called as “pinch point” and the analysis to find this temperature with respect to the laws of
thermodynamic is called as “Pinch Analysis” or “Pinch Technology”. Capital costs depend
mainly on the number of heaters, coolers, heat exchangers and their sizes (area) while operating
cost is mainly dominated by the need for external energy supplied such as heating and cooling.
Thus the main objective of pinch analysis is to achieve financial savings by better process heat
integration (maximizing the process heat recovery and reducing the external utility loads).
In table 1, the heating effect and cooling effect under steady state condition (constant heat
capacities and temperatures) are

Qheat = 10 x (420 – 90) + 32 x (350 – 170) + 29 x (390 – 200) = 14570 kW

Qcool = 27 x (510 – 300) + 2.0 x (440 – 140) = 13140 kW

which must be supplied by external heater and cooler such as steam water and cold water. The
idea is now to find the lowest possible Qheat for this particular problem.

3. The Pinch Method

The pinch method consists of two steps. In the first step the maximum energy recovery in the
system should be calculated which in turn reduces the external energy needed to a minimum
level.
Consider the process streams and it temperatures in table 1. Figure 3 shows the process
streams and the temperature intervals for the plant. The inlet and outlet temperatures can now be
divided into temperature intervals where the first temperature interval is between the largest
temperature and the second largest temperature. The next interval is between the second largest
temperature and the third largest temperature, etc. Such temperature intervals results are shown in
table 2.
For a given interval, one may calculated the amount of heat to be supplied to the plant (called
as Qheat) and how much how much heat must be taken from the plant (called as Qcool). The
relationship between these external cooling and heating can be written as
  
 Q  Q cool  Q heat . (1)

4
 
mCp
5 24

4 27

3 29

2 32

1 10

0 100 200 300 400 500 600

T [C]
Figure 3. Temperatures of the process streams.

Table 2. Temperature interval and external heating and cooling effects.

Interval Temperature Stream   

Number interval [C] Numbers Q cool Q heat Q

[kW] [kW] [kW]
1 510 – 440 5 1680 0 1680
2 440 – 420 4+5 1020 0 1020
3 420 – 390 1+4+5 1530 300 1230
4 390 – 350 1+3+4+5 2040 1560 480
5 350 – 300 1 + 2 + 3 + 4 +5 2550 3550 - 1000
6 300 – 200 1+2+3+4 2700 7100 - 4400
7 200 – 170 1+2+4 810 1260 - 450
8 170 – 140 1+4 810 300 510
9 140 – 90 1 0 500 - 500

For example in interval 4 where the temperature interval is between 390C to 350C, the cooling
and heating demands are:

Qheat = 10 x (390 – 350) + 29 x (390 – 350) = 1560 kW

Qcool = 27 x (390 – 350) + 24 x (390 – 350) = 2040 kW
Q = Qcool – Qheat = 2040 – 1560 = 480 kW

It means that a cooling effect of 480 kW must be supplied to the interval 4 so that the process
stream can deliver the lowest needed temperature which is 350C.

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 Another important conclusion from table 2 is that in interval 6 the need for external heating is
– 4400 kW which is the largest heating demand and must be supplied by external heating to the
process. In pinch method this external heating must be first supplied to the system at the
respective temperature interval and then all other temperature intervals must be updated
according to this heating demand.
There are two major methods to calculate the pinch point, table method and composite curve
method. The table method will be discussed next. However, in between the importance of Tmin
is going to be discussed first.

3.1 The meaning of Tmin

The interval and calculated heat transfer in table 2 requires an ideal heat transfer within a heat
exchanger that cool the hot stream down to the minimum temperature difference of Tmin = 0. It
means that the heat exchanger area (size) is infinite,

Tmin  0  heat exchanger size and price  .

This of course is not possible in practical applications and Tmin ≠ 0 is always valid. In order to
decrease the size of heat exchanger to an acceptable level with reasonable price it is assumed that
there always exists a temperature difference, preferably Tmin = 10C. This 10C can be treated
in three different ways. It can be added to the cold streams, which means that the cold streams are
warmed with 10C. Or, it can be divided between cold and streams which mean that the cold
stream will be warmer by 5C and the hot streams will be cooler by 5C. Finally, it can be
decreased from hot streams which in turn mean that the hot stream will be cooled by 10C.
Suppose that we choose the last option, although the hot streams cannot be fully warmed and
they will be cooler by 10C. A new temperature interval can thus be calculated which is specified
in table 3.

Table 3. Temperature interval for Tmin = 10C.

Interval Temperature Stream   

Number Numbers Q cool Q heat Q

interval [C]
[kW] [kW] [kW]
1 500 – 430 5 1680 0 1680
2 430 – 420 4+5 510 0 510
3 420 – 390 1+4+5 1530 300 1230
4 390 – 350 1+3+4+5 2040 1560 480
5 350 – 290 1 + 2 + 3 + 4 +5 3060 4260 -1200
6 290 – 200 1+2+3+4 2430 6390 -3960
7 200 – 170 1+2+4 810 1260 -450
8 170 – 130 1+4 1080 400 680
9 130 – 90 1 0 400 -400

3.2 The Problem Table Algorithm (PTA)

In this method the temperature intervals can be described as thermal blocks connected to each
other in series which is illustrated in Fig. 4. Every temperature interval can be regarded as a

6
network (or sub-network) that could be optimized with respect to the maximum energy recovery
within the process. Such coupling is also called as cascade coupling.

Q0,1 Q1,2 Q2,3 Qi-1,i Qi,i+1 Qn-1,n Qn,n+1

1 2 i n
From heater To cooler

D1 D2 Di Dn
Figure 4. Illustration of serial network connection.

The excess energy, which is usually called as deficit, for an arbitrary sub-network i can be
obtained from

     
Di  Ti  Ti 1    m C p    m C p   (2)
   cold   hot 

where Ti and Ti+1 corresponds to upper and lower temperatures in the arbitrary temperature
interval i. The important following condition is thus valid

Di < 0  need for cooling

Di > 0  need for heating

The energy balance for the arbitrary block i can be calculated by

 
Q i ,i 1  Q i 1,1  Di (3)

where Qi-1,i and Qi,i+1 are the supplied heat and removed heat respectively for each block. Table 4
shows the calculated supplied and removed heat for each temperature interval (block) as given in
table 1 and figure 3. Initially the supplied heat Q0,1 for block 1 is set to Q0,1 = 0.
The supplied heat Qi-1,i and the removal heat Qi,i+1 for any interval i are usually called as
sequential balance, which is illustrated in table 4. From table 4 it can be seen that Q6,7 , Q7,8 , Q8,9
and Q9,10 have negative values. These values are unreasonable because it would mean that heat is
moving from a lower temperature to a higher temperature. In order to create a reasonable
network, first the highest negative value must be found and then all the sequential balance values
must be added with this highest negative value (mathematically the lowest value). In the table, we
shall see that the highest negative value is – 1710 kW and this value must now be added to the
sequential balance values of Qi-1,i and Qi,i+1. The updated results are shown in the same table
(table 4) and are called as max table which refers to the last two columns at table 4. Table 4 is
usually called as cascade table.

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 From the last two columns of the table (Max table) three important values can be read. First,
the minimum external heat supply to enable the network working is read as 1710 kW. Second,
the minimum external cooling is 280 kW. Third, there exists a point where the heat flow between
the points is zero. This point is called the “pinch point” of the system.

Table 4. Sequential balance problem for the case in table 1 with Tmin = 10C.
Sequential Balance Max Table
Interval Temp. Di    

limits Q i 1,i Q i ,i 1 Q i 1,i Q i ,i 1

1 500 – 430 -1680 0 1680 1710 3390

2 430 – 420 -510 1680 2190 3390 3900
3 420 – 390 -1230 2190 3420 3900 5130
4 390 – 350 -480 3420 3900 5130 5610
5 350 – 290 1200 3900 2700 5610 4410
6 290 – 200 3960 2700 -1260 4410 450
7 200 – 170 450 -1260 -1710 450 0
8 170 – 130 -680 -1710 -1030 0 680
9 130 – 90 400 -1030 -1430 680 280

3.3 Importance of Pinch Point

Identification of the pinch point is very important when the process system consist of several
heat exchangers, coolers and heaters, in order to recover energy within the system with maximum
results and decrease the need for the external heating and cooling energy. Thus energy target can
be realized by designing an appreciate heat recovery network. The following rules immediately
are valid
- External coolers cannot be used above the pinch point (otherwise they should be heated
again)
- External heaters cannot be used below the pinch point (otherwise they should be cooled
again)
- Heat exchanger cannot be used across the pinch point because otherwise all heat flows
must be increased with this heat transferred.
Violation of any above rules results in higher energy requirements than the minimum
requirements theoretically possible. These rules are often called as pinch rules.
The pinch point divides the process into two separate systems which means that the areas
below and above the pinch point should be designed separately, when designing the process
network. Violation of any rules mentioned above results in higher energy requirements than the
minimum energy requirements that theoretically would be possible. Furthermore the following
conditions should be fulfilled at design closest to the pinch point
-  m C p    m C p  immediate above the pinch point
 
(4a)
  hot   cold
-  m C p    m C p  immediate below the pinch point
 
(4b)
  hot   cold

8
Due to several reasons such as safety reasons, corrosive media, pressure level, etc. some heat
exchangers cannot be used for some streams. Such limitations must be overcome with special
treatment, which are out of the scope of here and will not be further discussed.

3.4 Importance of Tmin

The driving force for heat transfer in a heat exchange is the average temperature difference
Tmin through Q = UATmin, where A is the heat exchanger area and U is the heat transfer
coefficient. For a given heat transfer coefficient the need for heat transfer area decreases with
increasing Tmin. For example, a heat exchanger with Tmin = 10C is about 90% smaller than a
heat exchanger with Tmin = 1C. Further, for Tmin = 20C the cost for external energy will
increases while the capital cost decreases. In addition, a balance between capital cost (heat
transfer area) and energy cost (external Qheat and Qcool) decides the optimum Tmin, as shown in
Fig. 5.
The capital cost for heat exchangers may have the form of a Area b + c while the energy cost
may be approximated as linear function of d (Qheat) + e (Qcool) which is a function for cost applied
to annual cost.

Total cost

Energy cost

Cost

Capital cost

Optimum Tmin

Tmin [C]
Figure 5. Different cost as function of Tmin.

Note that an increase of Tmin does not necessary give the same relative increase in
temperature difference between the streams everywhere. The biggest relative increase is obtained
close to the pinch point while the relative increase may be marginal away from this optimum
point.

3.5 Composite Curves

The problem with energy recovery within the system can also be illustrated graphically by
plotting the temperature – enthalpy curves. In order to do that the cold and hot streams shall be

9
treated separately and the temperature intervals may be decided similar to the problem table
algorithm method. Consider the streams for the process defined in table 1. The temperature
interval for the hot stream can be illustrated as shown in Fig. 6. Suppose that the temperature
interval is beginning from the lowest temperature to the highest temperature. The temperature
intervals with respective streams, heat capacity rates and enthalpy are also shown in table 5.
Three temperature intervals are found.

140C 300C 440C 510C


mCp

5 24

4 27

0 100 200 300 400 500 600

T [C]
Figure 6. Temperature intervals for the hot streams from table 1.

Table 5. Temperature intervals and enthalpy flow rates for hot streams only.
Interval Temperature Stream    

Number interval [C] Numbers  m C P  H  T  m C P   H

[kW/K] [kW] [kW]
1 140 – 300 4 27 4320 4320
2 300 – 440 4+5 51 7140 11460
3 440 – 510 5 24 1680 13140

550
500
450
400
350
300
T [C]
250
200
150
4320 7140 1680
100
50
0 15000
0 3000 6000 9000 12000
Enthalpy [kW]
Figure 7. Composite curve for hot streams.

10
In table 5, the enthalpy flow for any temperature interval can be calculated as the product of the
temperature difference and the sum of the heat capacity rates. Now the composite curve for hot
streams indicating the enthalpy – temperature diagram can be drawn for each temperature. Since
enthalpy is a relative value then the enthalpy for the first point (T = 140C) can be assumed to be
zero. Of course any other values can also be assumed. The results are shown in Fig. 7.
The cold streams can also be treated in the same way, see below. The illustration of the
temperature interval for the cold streams can be found in Fig. 8. The temperature interval for the
cold streams including the heat capacity rates and enthalpy are show in table 6. Five intervals are
found and for each temperature interval the enthalpy is the sum of all enthalpy for the previous
enthalpies.

200 390
90 170 350 420 
mCp
3 29

2 32

1 10

0 100 200 300 400 500 600

T [C]
Figure 8. Temperature intervals for the cold streams from table 1.

Table 6. Temperature intervals and enthalpy flow rates for cold streams only.
Interval Temperature Stream    

Number interval [C] Numbers  m C P  H  T  m C P   H

[kW/K] [kW] [kW]
1 90 – 170 1 10 800 280 – 1080
2 170 – 200 1+2 42 1260 1080 – 2340
3 200 – 350 1+2+3 71 10650 2340 – 12990
4 350 – 390 1+3 39 1560 12990 – 14550
5 390 – 420 1 10 300 14550 – 14850

The temperature – enthalpy diagram can now be included in composite curve of the hot streams.
The results are shown in Fig. 9. Note that from table method the external cooling was determined
to be

Q cool  280 kW

11
which is also the starting value (enthalpy) for the cold stream at 90C.
550
500
450
400 Hot composite
350
Pinch
T [C] 300 point Qheat
250
Cold composite
200
150
100 Qcool
50 QHeat Exchangers
0
0 3000 6000 9000 12000 15000
Enthalpy [kW]
Figure 9. Composite curves for hot and cold streams.

The pinch point in the composite curve is the point where the smallest temperature difference
(Tmin) between the hot composite and cold composite curves as indicated in Fig. 9. The external
cooling and external heating are the difference between the curves under and above pinch point
respectively. The overlapping area between the hot composite and cold composite curves is the
heat duty which is transferred in the heat recovery heat exchangers. The placement of the cold
composite curve is determined by the magnitude of the Tmin. Increasing the Tmin means that the
cold composite curve is shifted sideways in the enthalpy direction, see Fig. 10.
500

400
Hot composite
300
T [C]
Cold composite
200

100

0
0 3000 6000 9000 12000 15000
Enthalpy [kW]

Figure 10. Composite curves when the Tmin increasing.

12
3.6 Grand Composite Curve (GCC)
The cascade coupling of the heat flows shown in Fig. 4 can graphically be illustrated in a
temperature – heat flow (or enthalpy) diagram where each heat flow can be drawn against its
respective temperature interval as shown in Fig 10. This Grand Composite curve is drawn for
Tmin = 10C as was assumed in table 3 previously. The results for table 4 are graphically shown
in this figure. The GCC gives more detailed information about the process streams, external
heater and cooler utilities, etc. compared to the composite curves.

T [C]
550
Qheat Qheat

500 1710

1 - 1680
450
3390
3900
2
- 510 400
3 5130
- 1230
4
350 5610
- 480
5
1200 300
4410

6 3960 250

200 450
7 450 Pinch 0

8 - 680 150
680
9 400
100
280
Qcool
Qcool 50

0
0 1200 2400 3600 4800 6000

Heat flow [kW]

Figure 11. “Grand Composite” curve.

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4. Design of Heat Exchanger Network (HEN)

The design of new heat exchanger networks can be best executed by using the pinch method.
Using the pinch method incorporates two important features: a) it recognizes that the most
constrained part of the problem is the pinch region and b) designers are allowed to choose
between the match options. The designer examines which hot streams can be matched to the cold
stream by heat recovery. Every match brings one stream to its target temperature and the pinch
separates the heat exchanger systems into two thermally independent regions, heat exchange
networks above and below pinch temperature. When the heat recovery is maximized the
remaining thermal needs are supplied by external heat utility.
There is not any clear method in designing the HEN and therefore the designer shall try
different networks and finally find the optimal one. However, it is important to remember some
rules when designing the HEN
 The network above and below the pinch shall be designed separately (independently)
 Start with placing a heat exchanger close to the pinch point and continue outwards
 Allow the heat exchangers transfer heat as much as possible
 The need of heat load for hot streams shall be satisfied above the pinch point
 The criteria (4a) and (4b) mentioned previously are fulfilled

Sometimes it is necessary to split one stream in order to mach some loads. The following
diagram may help in splitting the streams. Suppose Nhot and Ncold are the number of hot and cold
streams respectively.

Nhot  Ncold Nhot  Ncold

Above Below
Pinch Yes No Pinch Yes No

m
   Split one cold m
   Split one hot
 Cp   m Cp   Cp   m Cp 
  hot   cold stream   hot   cold stream
for every pinch match ? for every pinch match ?

Yes No Yes No
Split one stream Split one stream
(usually hot) (usually cold)
a) b)
Figure 12. Flow diagram for splitting of streams a) above the pinch b) below the pinch.

In order to design the HEN for the example above it is useful to create tables in which the streams
specifications above and below the pinch temperature are shown, see tables 7 and 8. Note that the
pinch temperature was 170C, therefore, above the pinch the cold streams shall be heated from
170C while the hot streams must be cooled to 180C (if Tmin = 10C). In these tables such
aspects are also taken into account. As shown in the table there exist only one cold stream and
one hot stream below the pinch point (streams number 1 and 4).

14
 Table 7. Process streams above the pinch with Tmin = 10C .
Process stream Inlet Temp. Outlet Temp. Heat capacity rate 

Nr / Type [kW/K] Q [kW]

[C] [C]
1. cold 170 420 10 2500
2. cold 170 350 32 5760
3. cold 200 390 29 5510
4. hot 440 180 27 7020
5. hot 510 300 24 5040

Table 8. Process streams below the pinch with Tmin = 10C.

Process stream Inlet Temp. Outlet Temp. Heat capacity rate 

Nr / Type [kW/K] Q [kW]

[C] [C]
1. cold 90 170 10 800
2. cold – – – –
3. cold – – – –
4. hot 180 140 27 1080
5. hot – – – –


stream m CP
180C
5 24

5040
393.3
4 27

5760 470

3 29

790

2 32

1710
249
1 10

T [C]

170 240 320 400 480 560

Figure 13. Grid diagram above the pinch point.

15
Immediate above the pinch point, streams 4 and 2 fulfill the condition (4a), and table 7 shows
that the heat available from hot stream 4 can satisfy the needed heat for cold stream 2. The rest of
1260 kW (7020 – 5760 = 1260 kW) can be used for heat supply to other cold streams. An energy
balance provides the breaking temperature for stream 4,
5670 x 103 = 27 x 103 (T – 180)  T = 393.33C
These temperatures are far away from the pinch point and the condition (4a) is not in use any
more. Therefore, the rest heat of 1260kW can be used for any other cold streams. The hot stream
5 can provide 5040 kW needed heat for cold stream 3. Again, temperature 300C for stream 5 is
far away from pinch ant the condition (3a) is not valid any longer. Now the cold stream 3 needed
470 kW (5510 – 5040 = 470) which can be taken from rest of stream 4. After this, stream 4 has
790 kW left (1260 – 470 = 790) which can be given to the cold stream 1. The breaking
temperature for stream 1 can be calculated by
790 x 103 = 10 x 103 (T – 170)  T = 249C
The cold stream 1 needed now 1710 kW (2500 – 790 = 1710), which can be provided by external
heating. No split for any streams was needed since the conditions (4a) and (4b) were fulfilled
completely. The external heating is the same as was calculated previously. The results are
graphically illustrated in Fig. 13 which is usually called as Grid Diagram.
A similar treatment can also be done for stream below the pinch point, which is illustrated in
Fig. 14. The cold stream 4 needs 800 kW which can be provided by the hot stream 1 due to the
fact that the condition (4b) is fulfilled. The breaking temperature can be calculated through
energy balance equation as
800 x 103 = 27 x 103 (180 – T)  T = 150.37C
The hot stream 4 needs now 280 kW (1080 – 800) which can be supplied by the external cooling
utility.

stream m CP
150.37
4 27

280
800

1 10
T [C]

90 120 150 180

Figure 14. Grid diagram below the pinch point.

Now if grid diagrams in Figs. 13 and 14 are connected then the whole network can be graphically
shown in Fig. 15. Note that it is always useful to show the breaking points for the respective
stream in the grid diagrams in order to more exactly specify where the considered heat
exchangers are place. Another advantage is that by showing these breaking temperatures the
designer can easily realize how far these temperatures in comparison to the pinch point are place
and thus to understand whether the conditions (4a) and (4b) are relevant. Note that these
conditions are only valid immediately above or below the pinch point, not every where else.

16
 
stream m CP
180

5 24

150.37 5040 393.3

4 27
280 5760 470
3 29
800 373.79 790
2 32

249 1710
1 10

T [C]
170
100 200 300 400 500

Figure 15. Resulting grid diagram for the network.

4.1 Minimum Number of Heat Exchangers

At this point it might be interesting to mention the minimum number of heat exchangers units
that can be used in HEN designing. Below the pinch point the heat exchangers load is chosen so
that the cold streams are satisfied while above the pinch point the heat exchangers load is chosen
so that the hot streams are satisfied. As mentioned previously, to fulfill these conditions it is
sometime necessary to split some streams. Further, no heat transfer is allowed across the pinch
point in designing the Minimum Energy Requirement (often called as MER). Therefore, a
realistic target for the minimum number of units (UtargetMER) would be the sum of targets
evaluated at both above and below the pinch point separately as (Euler’s theory),

   
U t arg etMER  N hot  N cold  N utility  1 AbovePinch  N hot  N cold  N utility  1 BelowPinch (5)

where Nhot , Ncold and Nutility are number of hot streams, number of cold streams and number of
utilities (heaters and coolers) respectively. For the example above, below the pinch there are 2
streams and 1 heater, thus the minimum number of heat exchangers would be 2 +1 – 1 = 2 which
is also used in this HEN. Above the pinch, there are 5 streams (3 cold plus 2 hot) and 1 cooler
which results in 5 + 1 – 1 = 5 which is the minimum HEN and also is used in this solution HEN.
Note that the external cooling (1710 kW) and heating (280 kW) shall also be provided by heat
exchangers.
Moreover, the cost of heat exchangers should be in balance compared to other solution
methods such the need for more external heating and cooling. The target for minimum heat
transfer area and minimum number of heat exchanger units can be combined with the heat

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exchanger cost method to determine the target for the HEN capital cost. Note that the minimum
of units is of more interest in respect for cost of pipelines, fundaments, maintenance, etc.

5. Pinch Technology and Additional Points

As pointed out before the pinch technology offers a novel approach on designing a process
with maximal energy recovery network and thus minimizing the capital and maintenance cost.
Here some additional points will be pointed out which the designer shall be think.

5.1 Pinch Technology and Traditional Approach

In traditional designing approach, the core of process is designed with fixed flow rates and
temperatures so that the heat and mass balance of the process is satisfied. The design of heat
recovery systems are provided afterwards and the remaining duties are competed by using the
external utilities. In pinch technology approach integration of heat recovery systems is considered
together with process designing. A simple map in Fig. 16 shows clearly the differences.

Conventional Approach

Design of Heat Recovery Utility Systems

Core Heat
Process Exchangers

Pinch Technology Approach

Design of
Core
Process
Target Target
s s
Utility Systems Heat Recovery
Target Heat
s Exchangers
Figure 16. Traditional design approach versus pinch design approach.

5.2 Guidelines on Deciding the Magnitude of Tmin

In case information lack, the table below shows some guidelines on preliminary assumption
of Tmin for some different industrial processes.

Table 9. Some typical values for Tmin in industrial sectors.

Industrial Sector Typical values for Tmin
Low Temperature Process 3 – 5 C
Chemical 10 – 20 C
Petrochemical 10 – 20 C
Oil Refinery 20 – 40 C

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Note that the Tmin should be highly dependent on the flow type, heat exchanger type, sector to
be used, etc. For example, in oil refinery fouling is problem in the heat exchangers and therefore
Tmin would be large. Or power requirement for refrigeration process is very expensive and
therefore low value for Tmin is desired.

5.3 Steps of Pinch Analysis

A well defined stepwise procedure shall be followed in any pinch analysis problem, whether
it is a new project or it is retrofit situation (existing project to be updated). Note that it might be
necessary to iterate between some steps before continuing. Re-simulation and data modification
may also be useful in many situations.
- Identification of the cold streams, hot streams and utilities
- Thermal data extraction for the streams and utilities
- Tmin value selection
- Composite curves and grand composite curve construction
- Minimum energy cost target estimation
- Capital cost target estimation
- Optimum Tmin value estimation
- Practical targets for HEN design estimation
- HEN design

5.4 Benefits and Application Areas of Pinch Technology

Maybe one of the main advantages of the pinch technology over the traditional methods is the
ability of the pinch technology to set capital cost and energy recovery targets for a sub-process or
entire process ahead of design. Also, before designing any process the scope of energy savings
and investment requirements are known in advanced. In addition, the following process
improvements are among many that the pinch technology helps the process engineers to achieve.
- Updating/modifying the existing process flow diagram. It shows the areas that process
changes reduce the overall energy target.
- Process simulation studies. Old energy studies can be replaced by pinch technology
simulations so that information can be easily updated. It helps to avoid unnecessary
capital cost before the projects are implemented.
- Practical targets settings. Theoretical targets can be modified by taking into account
practical restrictions (safety, difficult handling fluids, temperature limit, pressure limit,
etc.).
- Determination of opportunities for Combined Heat and Power (CHP) process. Power cost
reduces significantly with a well designed CHP system. Pinch technology shows the best
possible CHP system that matches the thermodynamic targets on the site.
- Deciding what can be done with the low-grade waste heat. Pinch technology shows
which waste heat streams can be recovered effectively.

6. Pinch Method with Active Components of Heat Engines and Heat Pumps

Heat engines and heat pumps are the key components for the process utility systems. The idea
would therefore be the principles of placing these components into the process, or appropriate
integration of such devices into the process. Figure 17 shows the principle working mechanism

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of heat engines and heat pumps. A heat engine receives heat from a high temperature source and
produces work while emitting heat to a lower temperature source. A heat pump (refrigeration
mechanism) takes heat from a lower temperature reservoir by supplied work and rejects heat to a
high temperature source. The following relation is valid
  
W  Q1  Q 2 (6)

High High
Temperature Temperature
Source Source
Q1 Q1

Heat Heat
Engine Pump
W W
Q2 Q2

Low Temperature Low Temperature

Source Source
a) b)
Figure 17. Principles mechanism of a) heat engines and b) heat pumps (refrigeration).

6.1 Heat Engine (HE)

A heat engine in a process has two main objectives, supplying process heat demand and
generating power. An appropriate integration of heat engines into a process is important on
providing the most energy efficient combination of these objectives. By integration it means that
a heat exchange link is provided between the heat engine and the process. The integration of heat
engines into a process can be done on three different ways, above the pinch, below the pinch and
across the pinch. These integration possibilities are shown in Fig. 18.
Eheat  W Eheat  Q
    
Eheat – (Q – W) Eheat Eheat

HEN Q HEN Q HEN

above above above
pinch Q–W pinch pinch
HE
W
pinch pinch pinch
W
HE
HE
HEN HEN Q–W W HEN Q
below belo below
pinch w pinch
pinch Q–W
Ecool Ecool + (Q – W ) Ecool – Q
a) Above the pinch b) Across the pinch c) Below the pinch
Figure 18. Different integration possibilities of heat engines in a network.

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 If the heat engine is integrated so that it rejects heat to the network above the pinch
temperature (Fig. 18a), then heat will be transferred to the process heat sink. Therefore, network
hot utility demand will be reduced slightly and overall hot utility requirement is only increased
by engine shaft-work W. Such placement is appropriate because it implies 100% efficient heat
engine.
If the heat engine is placed so that it takes energy from the network below the pinch
temperature (Fig. 18c) then heat will be taken from overall process heat sources. It means that the
heat engine is running on free of fuel cost and overall cold utility requirement will be decreased
by engine shaft-work of W. Therefore, the heat engine is integrated appropriately.
If the heat engine is placed across the pinch temperature then both overall heat requirement
and overall cold requirement will be increased, as shown in Fig. 18b. Therefore, the heat engine
is integrated inappropriately.
To summarize, a heat engine placed either above the pinch or below the pinch are
appropriated, while a heat engine placed across the pinch is not appropriated.

6.2 Heat Pump (HP)

As pointed before a heat pump receives heat at a lower temperature and by using a
mechanical power rejects the heat at a higher temperature. The rejected heat is thus the sum of
input heat and the mechanical power. Key design parameters for heat pumps can be decided by
pinch analysis technology. Again, integration possibilities for heat pumps into a network process
can be done in three ways which are called as above the pinch, below the pinch and across the
pinch, see Fig. 19.
Eheat – W Eheat – (Q + W)

Q+W Eheat
HEN HEN
above above Q+W HEN
pinch Q pinch above
HP
pinch
W
pinch pinch
pinch
HP Q+W W
HEN HEN Q W HP
belo HEN
below
w below
pinch
pinch pinch Q
Ecool Ecool - Q Ecool + W
a) Above the pinch b) Across the pinch c) Below the pinch
Figure 19. Different integration possibilities of heat pumps in a network.

A heat pump can be placed so that it takes energy from the network above the pinch point and
reject heat to a higher temperature also above the pinch, see Fig. 19a. This integration possibility
decreases the overall heat demand by pump shift-work W in expense of an equal input power.
Therefore, such integration is inappropriate since the input power is more expensive than gained
heat.
In the second option, a heat pump can be integrated so that it takes energy from the network
below the pinch temperature and rejects heat to the temperature above the pinch, see Fig. 19b.
Such heat pump placement decreases the overall heating demand and overall cooling demand.

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The reduced overall heating and cooling demands is much bigger than the provided work to the
pump. Thus such integration possibility is appropriated.
The third option is that the heat pump is placed so that it takes energy from a point bellow the
pinch and rejects heat to a higher temperature which is also below the pinch, Fig. 19c. Such
integration increases the cooling demand with a value equal to the pump shaft-work W. This is
done in expense of an equal power provided for pump. Again, since the power is more expensive
than heat then such placement possibility is not appropriated.
To summarize, the only appropriate way to integrate a pump into a process is to place it
across the pinch. However, it is important to remind that the overall economic of a heat pump
depends on the heat saving when it is compared with the cost of input power, heat pump capital
cost and associated heat exchangers.

7. Process Modification by Plus – Minus Principle

In order to further decrease the overall energy requirement in a process, one needs to study
the composite curves (beside the process parameters such as operating pressure, operating
temperatures, reactor conversions, etc.). Since the composite curves strongly depend on the heat
and material balance of process, thus any changes in these parameters affect the composite
curves. Therefore, by applying the pinch rules mentioned above, one can easily identify the
changes in process parameter that have favorable impact on energy consumption.
The following rules are thus useful on studying the composite curves.
 The hot utility target reduces by:
- Any increase (+) in hot streams duty above the pinch
- Any decrease (–) in cold streams duty above the pinch
 The cold utility target reduces by:
- Any increase (+) in cold streams duty below the pinch
- Any decrease (–) in hot streams duty below the pinch
These simple rules are often called as “plus – minus principle” (+ / – principle) and are regarded
as guidelines for adjustment of a single heat duty. However, it is often possible to change process
temperature rather than its duty. The beneficial target for shifting the temperature can easily be
summarized as
 Shift hot streams from below the pinch to above the pinch
 Shift cold streams from above the pinch to below the pinch
These are in agreement with the general idea that it is beneficial to increase the hot streams
temperature (easier to extract energy) and reduce the cold streams temperature.

8. Pinch Technology and Future Possibilities

In late 1970s, the development of Pinch Technology started and it has found its place in
energy conversation applications. However, new developments for Pinch Analysis have been
done in other areas such as water use minimization, waste minimization, hydrogen management,
plastics manufacturing, etc. Below, some key research areas are pointed out.
 Water Pinch: In view of rising fresh water costs and more stringent discharge regulations,
Pinch Analysis may help companies to systematically minimize freshwater consumption
and wastewater volumes. Water Pinch is a technique that can be used for analyzing water
networks and reducing water costs for processes.

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 Hydrogen Pinch: Hydrogen Pinch is the pinch technology approach which applies to
hydrogen management technique. Using Hydrogen Pinch, a designer may be able to set
targets for the minimum hydrogen production from the plant or hydrogen imports without
the need for any process design. Hydrogen Pinch may also help for effective use of
hydrogen purification units.
 Top Level Analysis: Sometimes, it is very difficult to collect the required data in large
industrial areas. Which utilities are worth for saving can be determined by using a Top
Level Analysis with only efficiencies and constraints of the utility systems. Then data can
be gathered from those processes or units that use these utilities. Finally, a pinch analysis
can be performed on these equipment only.
 Total Site Analysis: Refinery and petrochemical processes operate usually as part of large
factories or sites. These sites have several processes which are serviced by a centralized
utility system. Via the main steam supplement, there might be both consumption and
recovery of the steam for different processes. In such large sites, different departments
usually control the individual process and the central services. These departments usually
operate independently. To improve integration of total site infrastructure, a simultaneous
approach to consider individual process issues and entire site utility planning is
sometimes necessary. Pinch Technology can therefore be used to calculate energy targets
for the entire site.
 Regional Energy Analysis: By studying the net energy demands of several companies
together (combined), the potential for sharing heat between these companies can be
identified. Such analyses may give insight into the amount of waste heat from these
industrial areas that might be available for export. Depending on the temperature level of
waste heat, it can also be used for power generation or district heating.

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Assignments

Problem 1: In a process site the following process streams are given. Suppose Tmin = 0C.

Process stream Inlet Temp. Outlet Temp. Heat capacity rate

Nr / Type [C] [C] [kW/K]
1. cold 20 135 2.0
2. cold 80 140 6.0
4. hot 170 60 3.0
5. hot 150 30 1.5

a) Perform the temperature interval.

b) Perform the sequential and max table.
c) Find out the external heating and cooling demands.
d) What is the pinch temperature?

(Answer: Qheat = 95 kW
Qcool = 15 kW
Tpinch = 80C)

Problem 2: A chemical site is going to be designed based on the following process streams. It is
also desired to recover maximum amount of heat through a network of heat exchangers.

Process stream Inlet Temp. Outlet Temp. Heat capacity rate

Nr / Type [C] [C] [kW/K]
1. cold 100 430 16.0
2. cold 180 360 32.4
3. cold 200 400 29.7
4. cold 260 400 22.4
5. hot 440 150 28.0
6. hot 520 300 23.8
7. hot 390 150 33.6

Assume Tmin = 10C for the heat exchangers.

a) Find out the temperature interval.
b) Perform the cascade table.
c) What are the minimal external and cooling effects?
d) What is the pinch temperature?
e) Draw the composite curves.
f) Draw the grand composite curve.
g) Draw the grid diagram.

(Answer: Qheat = 216 kW

Qcool = 1448 kW
Tpinch = 200C)

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Problem 3: Due to energy prices, a refinery is going to be modernized and at the same time
recover maximum energy in the site by using a complex network of heat exchangers.

Process stream Inlet Temp. Outlet Temp. Heat capacity rate

Nr / Type [C] [C] [kW/K]
1. cold 95 205 8.0
2. cold 40 220 8.0
3. cold 150 205 12.0
4. cold 65 140 20.0
5. hot 310 205 8.0
6. hot 245 95 13.0
7. hot 280 65 6.0

Answer to the following questions if Tmin for the heat exchangers is 10C. (Theoretical MER is
valid.)
a) Find out the temperature interval.
b) Draw the composite curves.
c) Perform the cascade table.
d) What are the minimal external and cooling effects?
e) What is the pinch temperature?
f) Draw the grid diagram for the heat exchangers.
g) Draw the grand composite curve.

(Answer: Qheat = 400 kW

Qcool = 0 kW
Tpinch = 40C)

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