Elements of Pinch Analysis

The majority of process plants contain a number of streams which need either to be heated or
cooled (known respectively as cold streams and hot streams). It is often immediately apparent
that some of the heating and cooling can be carried out by heat recovery between one or more
of the hot streams and one or more of the cold streams. On most of these plants, it is also
apparent that some heating and some cooling are actually being carried out by thermal
utilities, eg process steam, cooling water etc which results in a net energy cost to the site.

Composite curves

Pinch analysis is a systematic examination of thermally intensive processes in which all

heating and cooling duties (actual or potential) are extracted as temperature/energy flow
(T/H) profiles and combined into composite curves for the whole process and/or site. The
following diagrams illustrate the principle of composite curves and show how by combining
the hot and cold composites the total potential for heat recovery on the plant can be
quantified.

Role of Thermodynamics

First Law of Thermodynamics

Heat available in hot process streams and hot utilities

=
Heat required by cold process streams and cold utilities

QH + QHU = QC + QCU

Second Law of Thermodynamics

Tmin > 0

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The Pinch

This is the temperature region in a process where the hot and cold composites are closest
together. It is therefore the region where heat recovery is most constrained and it is most
important to ensure that heat transfer duties are correctly configured.

Above the pinch temperature there is a shortfall of heat and below it there is a surplus. The
majority of processes exhibit a pinch at some intermediate temperature between that of the
hottest and the coldest process stream. This is visible as the temperature at which the
composite curves are closest together.

A feature of all conventionally pinched processes is that all process heating below the pinch
and all process cooling above the pinch can be carried out by heat recovery. In order to
minimise thermal utility consumption it is therefore essential all heat available above the
pinch must be used above the pinch and all process heating below the pinch must be carried
out by heat recovery from below pinch hot streams. Likewise hot utilities should only be used
above the pinch and cold utilities should only be used below the pinch.

Pinch Design Method (PDM)

1. Use parallel grid diagram with pinch division, that appears as a vertical line (at a
temperature level).
2. Respect the pinch decomposition by designing in two separate regions with no cross-
pinch matches.
3. Decide on pinch matches first ;Start at pinch as this is the most constrained region.
4. Place away-pinch matches, heaters above pinch and coolers below pinch.
5. Check the design satisfies targets, and does not violate the Tmin constraint.

Feasibility Criteria For Pinch Matches

Above Pinch Below Pinch

Nhot < = Ncold Nhot > = Ncold

MCp,hot < = MCp,cold MCp,hot > = MCp,cold

1. identify match options that do not incur energy penalties (freedom available may be
exploited for other preferences like safety, plant layout, controllability, and operability)
2. dictate the essential matches
3. indicate the necessity for stream splitting

Essentially, PDM clarifies design options.

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Energy targeting

If a fixed minimum approach temperature (Tmin) is assumed to be applicable for all heat
transfer duties, pinch analysis can be used to target and design for minimum thermal utility
(energy) cost.

MCp(BTU/ Temp Temp

# Stream
hr F) Inlet (F) Outlet (F)

H1 Turbine Oil Base Stock 3852 400 130

H2 Vacuum Tower Bottom 78709 660 350
H3 Bottom Pump Around 166250 596 420
H4 Top Pump Around 78909 425 150
H5 SS 1 28571 478 135
H6 SS 2 37117 651 155
H7 SS 3 14455 685 180
C8 Boiler Feed Water 41538 250 406
C9 Boiler Feed Water 59200 250 366
C 10 Reduced Crude Oil 157149 300 480
C 11 Treated Water 95120 125 250

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Problem Table

Table : Temperture intervals and heat loads with cascading.

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Composite Curves

Figure : Hot and cold composite curves

This gives Pinch at 320 F .

We take Tmin = 40 F .

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Figure : Shifted Hot and Cold Composite Curve

Figure : Grand Composite Curve

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Heat Exchanger Network

Figure : Existing Network

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Figure : Proposed Network (based on pinch analysis).

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Heat Exchanger network comparison

Streams

Heat Exchanger Existing Revised

Hot Cold Duty Hot Cold Duty

E-101 H-3 C-8 29.3 H-3 C-8 29.3

E-102 H-6 C-9 10.4 H-4 C-11 9

E-103 H-7 C-9 4.5 H-5 C-9 3.9

E-104 H-7 C-11 2.8 H-4 C-9 2.96

E-105 H-6 C-11 3.3 H-4 C-9 3.4

E-106 H-6 C-11 3.3 H-4 C-10 3.3

E-107 H-6 C-11 1.4

E-108 H-5 C-8 2 H-4 C-8 2.1

E-109 H-5 C-9 4.4 H-7 C-8 4.4

E-110 H-5 SCW 3.3 H-5 SCW 2.95

E-111 H-4 C-8 4.5 H-5 C-11 2.9

E-112 H-4 C-11 1.1 H-7 C-10 0.6

E-113 H-4 SCW 16.1 H-6 SCW 6.8

E-114 H-2 C-10 24.4 H-2 C-10 24.4

E-118 H-1 SCW 1 H-1 SCW 1

H-6 C-9 11.5

New Exchangers Required H-7 SCW 2.3

H-4 SCW 0.9

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Savings due to change of LR VPS Heat Exchange Network from Pinch Analysis

Design efficiency of existing furnace F-101 - 83.5%

Existing Model

Furnace Heat Duty - 79.71 MM BTU/hr

Fired Heat duty - 95.46 MM BTU/hr

Fuel Oil Required - 22.20 TMTPA

After Pinch

Furnace Heat Duty - 76.1 MM BTU/hr

Fired Heat duty - 91.14 MM BTU/hr

Fuel Oil Required - 21.17 TMTPA

Savings in fuel oil - 1.03 TMTPA

Fuel Oil Cost - 40000 Rs/MT

Thus Total savings = Rs. 4.11 crores /annum

Basis:-

Calorific value of Fuel oil (LSHS) = 9500 Kcal/Kg

Cost of fuel oil per ton (LSHS) = Rs. 40000 /MT

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Results

Pinch point is found at 320 F.

Minimum Hot Utility required is 75.6 MM BTU/hr.

Minimum Cold Utility required is 13.91 MM BTU/hr.

Conclusions

Based on the Pinch Network Design, there is a potential to save 3.9 MM BTU/hr of furnance
duty , by increasing the Coil Inlet Temperature (CIT) from 455 F to 480 F. This results in a
saving of 1.03 TMTPA on fuel oil .

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