05 Pinch MF

Pinch Technology and optimization of
the use of utilities

Maurizio Fermeglia
mauf@dicamp.units.it
www.mose.units.it
Impact of process integration
Training Course on:

Sustainable Industrial Development: Process Simulation, Analysis, Optimization and Control
Mexico City - Mexico - September 2006 - slide
Which option requires more capital?
Training Course on:

Energy efficient process can also be more

capital efficient process (saves energy AND
capital)
Training Course on:

Energy efficient design reduces investment

in the utility infrastructure
Training Course on:

Pinch technology basics
Training Course on:

Training Course on:

How do I develop a network which

achieves the target?
Training Course on:

How can we identify appropriate

process design changes?
Training Course on:

Sustainable Development
Objectives and Process Integration
Social progress which
recognises the needs of
everyone
Effective protection of
the environment
Prudent use of natural
resources
Maintenance of high and
stable levels of
economic growth and
employment
Training Course on:

Process Integration
Introduce
Combined Heat and Power
(CHP)
OR..
Reduce Energy Consumption
Fuel
Crude
POWER
Steam for
Process HEATing
110
Heat
exchanger
network
80
Fuel
Reduce impact on climate change through efficient use

of resources (utilities)
Training Course on:
Sustainable Development by Process

Integration
Reduce
Reduce
Environmental
Environmental
Impact
Impact
Improve
Improve
Utility
UtilitySystem
System
Performance
Performance
Energy, Water, Hydrogen Utilities

Training Course on:
Sustainable Development by Process

Integration
Reduce
Reduce
Environmental
Environmental
Impact
Impact
Optimise
Optimise
Production
Production
Plan
Plan
Improve
Improve
Utility
UtilitySystem
System
Performance
Performance
Minimise
Minimise
Operating
Operating
Cost
Cost
All
AllAspects
Aspectsof
of
Debottlenecking
Debottlenecking
Capital
CapitalCost
Cost
Avoidance
Avoidance
Energy, Water, Hydrogen

Training Course on:
Introduction to Pinch technology

Whenever the design is considered limits exits that
constraints the design
Mechanical constraints
Length and diameter of towers
Diameters of heat exchangers
Thermodynamic constrains
First principles and second principles
Close approach in heat exchanger large surface area
Reflux ratio close to the minimum number of stages grows
When driving force becomes small area becomes large
We say that the design has a PINCH

Applies to heat and mass
In a network (mass or heat) there is a point in which the

driving force is minimum PINCH POINT
A succesful design involves defining where the pinch is
Using the information at the PINCH POINT is named PINCH
TECHNOLOGY
Training Course on:
Introduction to Pinch technology

Pinch technology applications
Both heat and mass transfer

New processes
Existing processes for retrofitting
Pinch technology = optimization

For new and existing processes an algorithm is used
Design of heat and mass exchanger network

that consumes the minimum amount of utilities HEN (MEN)
that requires the minimum number of equipments
(exchangers) MUMNE
The solution may not be optimal in the economic sense
it is a starting point close enough to the economic minimum.
Training Course on:

Pinch technology and heat integration

Growing importance of heat integration is driving force
Formalization of heat integration theory pinch technology
Linhoff and Flower

Hohman
Umeda et al.
Douglas
Turton et al (text book)
Different operative configurations of the same process may

result in
Same conditions (composition, temperature, pressure, flow rate)

Different Fixed capital investment
Different cost of utilities
Different Net present value
Training Course on:

DME reaction: different configurations

No Heat
integration
With heat
integration
Fixed capital investment
$ 346,000
$ 244,600
Cost of utilities
-$ 210,000 /yr
-$ 36,820 /yr
Net present value
-$ 1,636,000
-$ 471,000
Total saving (in the life of the plant) = -471,000 + 1,636,000 =$

1,165,000
Training Course on:

The MUMNE algorithm

The Minimum Utility steps:
Choose a minimum approach temperature (parametric

optimization)
Construct a temperature interval diagram
Construct a cascade diagram and determine the minimum utility
requirements and the pinch temperatures
Calculate the minimum number of heat exchangers above pinch
Calculate the minimum number of heat exchangers below pinch
Construct the heat exchanger network
The object is to obtain and heat exchanger network
That exchange the minimum energy between the streams and

the utilities
That uses the minimum number of equipment
Training Course on:

Algorithm: initial condition and step 1

Minimum Temperature Approach = Smallest T of two streams
leaving or entering an heat exchanger = 10C
Hot Stream Data
Mass Flow Cp
Temp In
kg/s
kJ/kg/C
C
10.00
2.500
3.000
.8000
.8000
1.000
300.0
150.0
200.0
Temp Out
C
150.0
50.00
50.00
Cumulative Hot Stream Energy Available =

Cold Stream Data
Mass Flow Cp
Temp In
kg/s
kJ/kg/C
C
6.250
10.00
4.000
.8000
.8000
1.000
190.0
90.00
40.00
Temp Out
C
290.0
190.0
190.0
Stream Enthalpy
kW
1200.
200.0
450.0
1850.0
Training Course on:

400.0
270.0
530.0
kW
Stream Enthalpy
kW
-500.0
-800.0
-600.0
Cumulative Cold Stream Energy Available = -1900.0
Film Heat Transf. Coef

W/m2/C
Film Heat Transf. Coef

W/m2/C
100.0
250.0
80.00
kW
Algorithm: construct Temperature interval

diagram (step 2)
Process streams represented by vertical lines
Axes are shifted by the minimum T approach (10C)
Training Course on:

Algorithm: construct a cascade

diagram (1)
Shows the net amount of energy in each interval

diagram
Cascade if there is an excess energy in a T interval
we may cascade it down
Energy cannot be transferred up (II law)
Line is the point at which no more energy can cascade
down
We need to resort to utilities
NOTE: not all problems have a pinch condition: the
algorithm is still valid
Pinch
temperature
Training Course on:

Algorithm: construct a cascade

diagram (2)
Additional heat is transferred to the C interval (yellow line)

Energy is cascaded down through the pinch and rejected to
the cold utility
If heat is transferred across the pinch, the net result will be
that more heat will have to be added from the hot utility and
rejected to the cold utility
To minimize the hot and cold utility requirements,
energy should NOT be transferred across the pinch
Pinch
temperature
Training Course on:
Algorithm: minimum n. of exchangers

Above the pinch
Draw boxes representing energy in the hot and cold
process streams and utilities
Transfer energy is indicated by lines (with the amount)
For each line an heat exchanger is required
The problem is split into two sub problems
Training Course on:


Below the pinch
Draw boxes representing energy in the hot and cold
process streams and utilities
Transfer energy is indicated by lines (with the amount )
For each line an heat exchanger is required
The problem is not split into sub problems
Training Course on:


General relationship
For any sub problem

With or without a pinch
Above or below the pinch
Min. No. of exchangers = No. of hot streams + No. of cold

streams +
No. of utilities 1
Training Course on:

Algorithm: Design the network above the

pinch
Start from the design at the
pinch
To make sure that T min is
not violated, match
streams such that
m c p , IN m c p ,OUT
m c p ,hot m c p ,cold
Note that we consider ONLY
streams present at the
pinch
Each exchanger is
represented by two circles
connected with a line, each
circle represent a side
Training Course on:
Algorithm: Design the network above the

pinch
Move away from the pinch
Look at the remaining
streams
Criterion used at pinch not
necessarily holds away
from the pinch
The following constraints
are not violated:
The minimum approach T is

used throughout the design
The number of exchangers
must be that calculated in
step 3
Heat is added form the
coolest possible source
Training Course on:

Algorithm: Design the network below the

pinch
Similar to previous one: start
from the design at the pinch
To make sure that T min is not
violated, match streams such
that
m c p , IN m c p ,OUT
Note that we consider ONLY
streams present at the pinch
Each exchanger is represented
by two circles connected with a
line, each circle represent a side
What happens if the T min is
violated (see figure)
Training Course on:


pinch
Split stream into
substreams to
meet the T min
criterion
Training Course on:


pinch
Move away from the pinch
Look at the remaining
streams
Training Course on:

Final result
The final network of
heat exchangers is the
following
It has the minimum n. of

exchangers (8)
Minimum utility
requirement (Qh = 100
kW and Qc = 50 kW)
Using a minimum
approach T = 10
Training Course on:

Heat exchangers design: area and

costs
Up to now, emphasis on the topology of the network
to complete the design, it is necessary to
Estimate the heat transfer area (A= Q / (U Tln F)
And the cost estimate
If heat transfer coefficients are known (including fouling)
Transfer coefficients form literature (Seider Tate, Donahue, )
exchanger area can be calculated (for streams exchangers)

Exchanger DT ln
U
Q
F factor
Area.
C
W/m2/C
kW
m2
1
24.1
129.8
100
0.8
40.0
2
20.0
69.5
300
0.8
270.3
3
47.5
153.8
700
0.8
119.7
4
24.1
80.0
500
0.8
324.6
6
10.0
61.7
100
0.8
202.5
7
17.0
69.5
100
0.8
195.8
TOTAL
1063.0
Exchanger 5 requires an hot utility (steam): T = 76.8 C, U= 76.9 W/m2/C, Area = 16.9 m2
Exchanger 8 requires cooling water: T = 23.2 C, U= 346 W/m2/C, Area = 7.8 m2
TOTAL Area: 1087.7 m2

Training Course on:
Effect of the minimum approach

temperature
Calculations must be repeated for different approach T
(step 1)
Problem: step 5 (matching streams and exchanging
energy) cannot be programmed easily
An approximate approach is necessary for investigating
the effect of the approach temperature on the total cost
Based on the Composite temperature enthalpy diagram
Constructed by plotting enthalpy of all streams as a function of T
Training Course on:

Construction of Composite T-H

diagram
Temperatur T C Enthalpy of HOT streams in
Cumulative
e Interval
D
Temperature interval (kW)
Enthalpy of HOT
streams (kW)
50 0
100 (2+3)(100-50) = 250
250
150 (2+3)(150-100) = 250
500
200 (8+3)(200-150) = 50
1050
300 (8)(300-200)
1850
Temperatur
e Interval
T C
= 800
Enthalpy of COLD streams in

Temperature interval (kW)
40 0
90 (4)(90-40)
Cumulative
Enthalpy of COLD
streams (kW)
0
= 200
200
140 (8+4)(140-90) = 600
800
190 (8+4)(190-140) = 600
1400
Training Course on:

Construction of Composite T-H

diagram
Training Course on:

Using the T-H diagram to estimate heat

exchanger area
The working equation is (A= Q / (U Tln F)
Consider a portion of the diagram (figure)
Training Course on:

Results of the heat transfer area

calculations
Training Course on:

Finalize the design

Consider the F factor
By calculating the number of shells in a 1-2 geometry exchanger

The effect of the economy of scale: the cost of two 1-2 S&T in series
is greater than the equivalent 1-2 S&T with the same total area
Calculate the cost of equipments
Knowing the number of shells for each exchanger

Using cost correlations
Applying an economic criteria (such as Equivalent Annual Operating
Cost EAOC)
Approximations
All heat exchangers have the same area over estimation of the
costs
No effect of material of construction (corrections available)
No effect of operating pressure (corrections available)
No multiple utilities (alternative methods)
No streams with phase change (correction available)
Training Course on:

Calculation of the costs for the

network
Training Course on:

Typical relationship for heat transfer area,

utilities and EAOC for a HEN
Training Course on:

Mass exchange networks

Exchangers to use energy
more efficiently
Temp Interval Diagram
Cascade diagram pinch
Min n. of eq. above and
below
Composite T exchange diag.
Final T exchange network
Utility: cold and hot source
of energy
Hot and cold
Temperature
Training Course on:

Separators to use mass more

efficiently
Composition Interval Diagram
Cascade diagram pinch
Min n. of eq. above and below
Composite mass exchange
diag.
Final mass exchange network
Utility: separation - addition of
solute (from source or to sink)
Rich and lean
Concentration

05 Pinch MF

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

05 Pinch MF

Uploaded by

Copyright:

Available Formats

Pinch Technology and optimization of

the use of utilities

Impact of process integration

Training Course on:

Mexico City - Mexico - September 2006 - slide

Which option requires more capital?

Training Course on:

Mexico City - Mexico - September 2006 - slide

Energy efficient process can also be more

Training Course on:

Mexico City - Mexico - September 2006 - slide

Energy efficient design reduces investment

Training Course on:

Mexico City - Mexico - September 2006 - slide

Pinch technology basics

Training Course on:

Mexico City - Mexico - September 2006 - slide

Training Course on:

Mexico City - Mexico - September 2006 - slide

How do I develop a network which

Training Course on:

Mexico City - Mexico - September 2006 - slide

How can we identify appropriate

Training Course on:

Mexico City - Mexico - September 2006 - slide

Training Course on:

Mexico City - Mexico - September 2006 - slide

Reduce Energy Consumption

Reduce impact on climate change through efficient use

Mexico City - Mexico - September 2006 - slide

Sustainable Development by Process

Energy, Water, Hydrogen Utilities

Mexico City - Mexico - September 2006 - slide

Sustainable Development by Process

Energy, Water, Hydrogen

Mexico City - Mexico - September 2006 - slide

Introduction to Pinch technology

When driving force becomes small area becomes large

We say that the design has a PINCH

In a network (mass or heat) there is a point in which the

Mexico City - Mexico - September 2006 - slide

Introduction to Pinch technology

Both heat and mass transfer

Pinch technology = optimization

Design of heat and mass exchanger network

Training Course on:

Mexico City - Mexico - September 2006 - slide

Pinch technology and heat integration

Linhoff and Flower

Different operative configurations of the same process may

Same conditions (composition, temperature, pressure, flow rate)

Training Course on:

Mexico City - Mexico - September 2006 - slide

DME reaction: different configurations

Fixed capital investment

Net present value

Total saving (in the life of the plant) = -471,000 + 1,636,000 =$

Training Course on:

Mexico City - Mexico - September 2006 - slide

The MUMNE algorithm

Choose a minimum approach temperature (parametric

The object is to obtain and heat exchanger network