PART 4

PINCH DESIGN METHOD

MAXIMUM ENERGY
RECOVERY NETWORKS
 MER NETWORKS
• Networks featuring minimum utility usage are
called MAXIMUM ENERGY RECOVERY
(MER) Networks.
 DIVISION AT THE PINCH
RECALL THAT
• No heat is transferred through the pinch.
• This makes the region above the pinch a
HEAT SINK region and the region below
the pinch a HEAT SOURCE region.
 Heat Sink
Minimum
Heat is obtained from 7.5
heating utility
the heating utility 1.5

9.0

-6.0
T
3.0

1.0

4.0

-4.0

0.0 Pinch
14.0

14.0

-2.0

12.0
H
-2.0
Minimum
Heat Source 10.0
cooling utility
Heat is released to
cooling utility
 CONCLUSION
• One can analyze the two systems separately,
that is,

• Heat exchangers will not match streams

above the pinch with streams below the
pinch
 PINCH MATCHES
• Consider two streams above the pinch
TC,out= Tp- ΔTmin + Q/FCpC
TH,in Tp
TH,in= Tp+Q/FCpH
But TH,in> TC,out+ ΔTmin.
Thus replacing one obtains Q/FCpH > Q/FCpC

TC,out Q Tp- ΔTmin FCpH < FCpC Golden rule for pinch
matches above the pinch.

ΔTmin ΔTmin Violation when FCpH > FCpC

 Below the Pinch
TC,in= Tp- ΔTmin - Q/FCpC
Tp TH,out
TH,out= Tp-Q/FCpH
But TH,out> TC,in + ΔTmin.

Thus replacing one obtains

Q TC,in Golden rule for pinch

FCpC < FCpH
Tp- ΔTmin matches below the pinch.

ΔTmin ΔTmin

Violation when FCpC > FCpH

 CONCLUSION
• Since matches at the pinch need to satisfy these rules,
one should start locating these matches first. Thus, our
first design rule:

START BY MAKING PINCH

MATCHES
 TICK-OFF RULE
Once a match has been selected how much heat
should be exchanged?

• As much as possible! (We want to minimize units, so

once we have one, we make the biggest use of it
possible)
• This means that one of the streams has its duty
satisfied!!
 HANDS ON EXERCISE
ΔH=27 MW ΔH=-30 MW

T=230 0C REACTOR 2
T=140 0C T=80 0C
T=200 0C

ΔH=32 MW ΔH=-31.5 MW
REACTOR 1
T=20 0C
0C
T=250 0C T=40 0C
T=180

Stream Type Supply T Target T ΔH F*Cp

(oC) (oC) (MW) (MW oC-1)
Reactor 1 feed Cold 20 180 32.0 0.2
Reactor 1 product Hot 250 40 -31.5 0.15
Reactor 2 feed Cold 140 230 27.0 0.3
Reactor 2 product Hot 200 80 -30.0 0.25

ΔTmin=10 oC PINCH=150 oC
 HANDS ON EXERCISE
250 0C 150 0C 40 0C
FCp=0.15 H1
200 0C
80 0C
FCp=0.25 H2

180 0C 140 0C 20 0C
FCp=0.2 C1

FCp=0.3 230 0C C2

Stream Type Supply T Target T ΔH F*Cp

(oC) (oC) (MW) (MW oC-1)
Reactor 1 feed Cold 20 180 32.0 0.2
Reactor 1 product Hot 250 40 -31.5 0.15
Reactor 2 feed Cold 140 230 27.0 0.3
Reactor 2 product Hot 200 80 -30.0 0.25

ΔTmin=10 oC PINCH=150 oC
 ABOVE THE PINCH

250 0C 150 0C
FCp=0.15 H1

200 0C
FCp=0.25 H2

180 0C
C1
FCp=0.2
230 0C
FCp=0.3
C2
140 0C

• Which matches are possible?

 Pinch matches above the Pinch
150 0C
250 0C
FCp=0.15 H1

200 0C
FCp=0.25 H2

180 0C
FCp=0.2 C1
230 0C
FCp=0.3 C2
140 0C

• The rule is that FCpH < FCpC .

• The candidates are: H1-C1, H1-C2 and H2-C2.
• Because all hot streams at the pinch need to participate
in a pinch match, we therefore can only choose the
matches H1-C1 and H2-C2.
 Pinch matches above the Pinch
250 0C 203.3 0C 150 0C
FCp=0.15 H1

200 0C
FCp=0.25 H2

180 0C
FCp=0.2 C1
230 0C 181.7 0C 8
FCp=0.3 C2
140 0C
12.5

• The tick-off rule says that a maximum of 8 MW is exchanged

in the match H1-C1 and as a result stream C1 reaches its target
temperature.
• Similarly 12.5 MW are exchanged in the other match and the
stream H2 reaches the pinch temperature.
 Pinch matches below the Pinch
150 0C 40 0C
FCp=0.15 H1

FCp=0.25 H2 80 0C

FCp=0.2 140 0C 20 0C C1

• The rule is that FCpC < FCpH .

• Only one match qualifies: H2-C1
• Below the pinch all cold streams need to
participate in pinch matches
 ANSWER (below the pinch)

FCp=0.15 H1 150 0C 40 0C

FCp=0.25 H2 80 0C

FCp=0.2 140 0C 52.5 0C 20 0C

C1

17.5

• The tick-off rule says that a maximum of 17.5 MW is

exchanged in the match H2-C1 and as a result stream H2
reaches its target temperature.
 COMPLETE NETWORK
AFTER PINCH MATCHES
250 0C 203.3 0C 150 0C 40 0C
FCp=0.15 H1

H2 200 0C 80 0C
FCp=0.25

140 0C
180 0C 52.5 0C
FCp=0.2 C1
20 0C

0 8 17.5
FCp=0.3 230 0C 181.7 C C2
140 0C

12.5

• Streams with unfulfilled targets are colored.

 NON-PINCH MATCHES
203.3 0C 150 0C 40 0C
FCp=0.15 H1 250 0C

H2 200 0C 80 0C
FCp=0.25

140 0C
180 0C 52.5 0C
FCp=0.2 C1
20 0C
181.7 0C 8 17.5
FCp=0.3 230 0C C2
140 0C
12.5

• Away from the pinch, there is more flexibility to make

matches, so the inequalities do not have to hold.
• The pinch design method leaves you now on your own!!!!!
• Therefore, use your judgment as of what matches to select!!
 NON-PINCH MATCHES
250 0C 203.3 0C 150 0C 40 0C
FCp=0.15 H1

H2 200 0C 80 0C
FCp=0.25

140 0C
180 0C 52.5 0C
FCp=0.2 C1
20 0C

181.7 0C 8 17.5
FCp=0.3 230 0C C2
140 0C
12.5

• We first note that we will use heating above the pinch. Thus
all hot streams need to reach their inlet temperature. We are
then forced to look for a match for H1.
 NON-PINCH MATCHES
• The match is H1-C1. We finally put a heater on the
cold stream

250 0C 150 0C 40 0C
FCp=0.15 H1

H2 200 0C 80 0C
FCp=0.25

140 0C 52.5 0C
180 0C
FCp=0.2 C1
20 0C
230 0C 8 17.5
FCp=0.3 C2
H
140 0C
7.5 7 12.5
 NON-PINCH MATCHES
• Below the pinch we try to have the cold streams start at
their inlet temperatures and we later locate coolers (one in
this case).

250 0C 150 0C 40 0C
FCp=0.15 H1 C
10
200 0C
FCp=0.25 H2
80 0C

180 0C 140 0C 20 0C
FCp=0.2 C1

230 0C 8 17.5 6.5

FCp=0.3 C2
H
140 0C
7.5 7 12.5
 UNEQUAL NUMBER OF
STREAMS AT THE PINCH
Indeed, if the number of hot streams is larger than the
number of cold streams, then no pinch matches are
possible. Consider this (new) example:
150 OC 100 OC Assume the matches H1-C1 and
FCp=0.15 H1
the matches H2-C2 have been
FCp=0.25 140 OC
H2 selected. Since H3 needs to go to
130 OC the pinch temperature, there is no
FCp=0.1 H3
cold stream left to match, even if
127.5 OC 90 OC there is portions of C1 or C2 that
Target=170 OC FCp=0.2
C1 are left for matching. Such
122.5 OC
Target=140 OC FCp=0.4
7.5 matching would be infeasible.
C2
10

What is then, the solution?

 UNEQUAL NUMBER OF
STREAMS AT THE PINCH
Split cold stream until the inequality is
satisfied.
150 OC 100 OC
FCp=0.15 H1
140 OC
FCp=0.25 H2
130 OC
FCp=0.1 H3

OC
127.5 OC 90 OC
Target=170 FCp=0.2 C1

130 OC 7.5
Target=140 OC FCp=0.25 C2
FCp=0.15 110 OC 10

3
Notice that different combinations of flowrates in the split
satisfy the inequality.
 UNEQUAL NUMBER OF
STREAMS AT THE PINCH
Above the pinch, we notice the following rule

SH ≤SC

If that is NOT the case, we split a cold stream until SH=SC

A similar rule can be discussed below the pinch, that is,

SH ≥SC

If that is NOT the case, we split a cold stream until SH=SC

 INEQUALITIES NOT SATISFIED
Consider the following caseabove the pinch
We notice that FCpH >FCpC (needs to be FCpH ≤FCpC)

150 OC 100 OC
FCp=0.5 H1

90 OC
Target=170 OC FCp=0.2 C1

Target=140 OC FCp=0.4 C2
INEQUALITIES NOT SATISFIED
The hot stream needs to be split

FCp=0.2 H1 150 OC 100 OC

FCp=0.3

140 OC 90 OC
Target=170 OC FCp=0.2
C1

127.5 OC 10
Target=140 OC FCp=0.4
C2

15
INEQUALITIES NOT SATISFIED

Below the Pinch :

100 OC
FCp=0.5 H1 Target=40 OC

FCp=0.3 H2 Target=20 OC

90 OC 30 OC
FCp=0.7 C1
INEQUALITIES NOT SATISFIED
The cold stream needs to be split
100 OC 40 OC
FCp=0.5 H1 Target=40 OC

FCp=0.3 H2 Target=20 OC
60 OC

90 OC 30 OC
FCp=0.5 C1
30
FCp=0.2
12
COMPLETE PROCEDURE
ABOVE THE PINCH

Start

Yes FCpH≤FCpC Yes

SH≤SC
at pinch?

No No

Split Cold
Stream

Place Split Hot

matches Stream
COMPLETE PROCEDURE
BELOW THE PINCH

Start

Yes FCpH ≥ FCpC Yes

SH≥SC
at pinch?

No No

Split Hot
Stream

Place
Split Cold
matches
Stream
HANDS ON EXERCISE
Type Supply T Target T F*Cp
(oC) (oC) (MW oC-1)
Hot 750 350 0.045
Hot 550 250 0.04
Cold 300 900 0.043
Cold 200 550 0.02

ΔTmin=50 oC
Minimum Heating Utility= 9.2 MW
Minimum Cooling Utility= 6.4 MW
 ANSWER
FCp=0.04 550 0C
750 0C 358.89 0C
350 0C
FCp=0.045 H1

0.4
250 0C
FCp=0.04 H2

686.05 0C 6
400 0C

300 0C
FCp=0.043 900 0C C1

9.2 8 8.6
FCp=0.02 550 0C C2
200 0C
1 500 0C 6
NOTE ON UNIT TARGETING

Nmin= (S-P)above pinch+ (S-P)below pinch

If we do not consider two separate problems,

above and below the pinch we can get
misleading results.
 EXAMPLE 150 0C
FCp=0.15 H1 250 0C 40 0C
C
10
H2 200 0C
FCp=0.25
80 0C

180 0C 140 0C 20 0C
FCp=0.2 C1

230 0C 8 17.5 6.5

FCp=0.3 C2
H
140 0C

7.5 7 12.5

Nmin= (S-P)above pinch+ (S-P)below pinch =

=(5-1) + (4-1) = 7
If we do not consider two separate problems
Nmin= (6-1)= 5, which is most of the time wrong
Note: A heat exchanger network with 5 exchangers exists, but it is impractical and
costly. This is beyond the scope of this course.