Heat Exchanger Network

Synthesis (HENS)

PROF. RASHMITA PATEL

PINCH DESIGN METHOD (PDM)
FOR HEN SYNTHESIS
  Varying ΔTmin , as shown in
Figure, changed the relative
position of the process composite
curves.
 As ΔTmin is changed from a small
to a large value, the capital cost
decreases but the energy cost
increases.
 When the two costs are combined
to obtain a total cost, the optimum
point in the capital-energy trade-
off is identified, corresponding
with an optimum value of Δ Tmin

Fig. The correct setting for ΔTmin is

fixed economic trade-offs.
 Continue…

 The tradeoff between energy and capital cost suggests a good

initialization would be to assume that no individual exchanger
should have a temperature difference smaller than ΔTmin .
 To comply with this, the process should be divided at the pinch.
this is most clearly done by representing the stream data in the
grid diagram.
 Figure in next slide shows the stream data from Table in grid form
with the pinch marked.
 Above the pinch, steam can be used (up to QHmin ), and below the
pinch cooling water can be used (up to QCmin ) as utilility.

 But what strategy should be adopted for the design? A number of

simple criteria can be developed to help.
HOT PINCH TEMPERATURE: 150oc
COLD PINCH TEMPERATURE: 140oc
 THE PINCH DESIGN METHOD


 Criteria for PINCH DESIGN METHOD

1. Start at the pinch.:

 The pinch is the most constrained region of the problem.
At the pinch, ΔTmin exists between all hot and cold
streams. As a result, the number of feasible matches in this
region is severely restricted. Quite often there are essential
matches to be made.
 2. Stream population criteria

For Above Pinch Region:

For Below Pinch Region:

3. The CP inequality for individual matches.
Above Pinch

 On the other hand, Figure b

shows a match involving the
same hot stream but with a
cold stream that has a larger
CP.
 The relative slopes of the
temperature–enthalpy
profiles now cause the
temperature differences to
become larger moving away
from the pinch, which is
feasible.
 Thus, starting with ΔTmin at
the pinch, for temperature
differences to increase
moving away from the pinch.
Below Pinch

 If the same cold stream is

matched with a hot stream
with a larger CP (i.e. a less
steep slope), as shown in
Figure b, then temperature
differences become larger,
which is feasible.
 Thus, starting with ΔTmin
at the pinch, for
temperature differences to
increase moving away from
the pinch
CP Table for Above Pinch
CP Table for Below Pinch
 The “tick-off” heuristic:
 Once the matches around the pinch have been chosen to satisfy
the criteria for minimum energy, the design should be continued
in such a manner as to keep capital costs to a minimum.
 One important criterion in the capital cost is the number of units
(there are others, of course, which shall be addressed later).
 Keeping the number of units to a minimum can be achieved
using the tick-off heuristic.
 To tick off a stream, individual units are made as large as
possible, that is, the smaller of the two heat duties on the streams
being matched.
HOT PINCH TEMPERATURE: 150oc
COLD PINCH TEMPERATURE: 140oc
 THE PINCH DESIGN METHOD


 Above Pinch

250oC 150oC
2 √ 15 MW

200oC √
4 150oC 12.5MW

Feasible

180oC
√ 1 140oC 8MW

8MW
230oC H 3 27MW
140oC
7.5 12.5 7
MW MW MW
 250oC √ 150oC
15 MW
2 0.5
MW
200oC
4 C 150oC 12.5MW

Infeasible

140oC 8MW
180oC H 1
8
230oC MW 3
140oC 27MW
12 15
MW MW
BELOW PINCH

16.5 MW
17.5MW

24MW
The completed design for the given data
• No. of Heat Exchanger used above pinch region
(including cold utility): 04

• No. of Heat Exchanger used below pinch region

(including cold utility): 03

• Therefore,
Total no. of Heat Exchanger used are: 07

• Minimum no. of HE required theoretically=

• =(Sabove Pinch-1)+(Sbelow pinch -1)
= (5-1)+(4-1)
=7
PINCH DESIGN METHOD STEPS
 Above Pinch

400oC √ 120oC
1 84 MW

210oC √ 45MW
2 120oC

160oC
√ 3 100oC 24MW

24MW
300oC H 4 120MW
100oC
15MW 60MW 45MW
Stream splitting algorithms
GRID DIAGRAM & CP TABLE
 ABOVE PINCH

CP √
CP 0.040
CP
0.045 0.005
720oC √ 520oC 8 MW
9.0
1 1 MW
MW

0.043 17.2
500oC17.2
0.043
900oC H 3 MW MW
0.020
0.020 9.2 MW 8MW
550oC 4 500oC
1 MW 1 MW
√
1MW
 Below Pinch

CP
520oC 320oC
0.045 1 9 MW
0.040 220oC
520oC 2
12 MW

0.043 500oC √ 3 300oC 8.6 MW

0.020 8.6MW 6 MW
500oC 4 200oC

6MW √
8 MW
1 MW 9 MW

12 MW

8.6
17.2 MW
MW
6 MW

1 MW
 Example : The stream data for a process are given in Table below:
Steam is available condensing between 180 and 179◦C and cooling water
between 20 and 30◦C. All film transfer coefficients are 200 W·m−2·K−1.
For Tmin = 10◦C, the minimum hot and cold utility duties are 7 MW and
4 MW respectively, corresponding with a pinch at 90◦C on the hot
streams and 80◦C on the cold streams.
 a. Develop a maximum energy recovery design above the pinch that
comes close to the area target in the minimum number of units.
 b. Develop a maximum energy recovery design below the pinch that
comes as close as possible to the minimum number of units.
 Above Pinch

150oC √ 90oC
1 12 MW

170oC √
2 90oC 8 MW

120oC
√ 3 80oC 12 MW

12 MW
110oC H 4 15 MW
80oC
7 MW 8 MW