Major Project

on

Pinch Analysis & Process Integration

Mid-Review Report

Submitted by-

Bibek Singh Mer (R900214021)

Rajat Batish (R900214053)

Shrey Jain (R900214060)

Tushal Soni (R900214067)

Under the guidance of

Mr. Giridhar Vadicharla

(Assistant Professor)

DEPARTMENT OF CHEMICAL ENGINEERING

COLLEGE OF ENGINEERING STUDIES

UNIVERSITY OF PETROLEUM & ENERGY STUDIES

Bidholi Campus, Energy Acres, Dehradun-248007.

Objective:
Objectives of this project are:

1. Study of pinch analysis or pinch technology.

2. To minimize energy requirement of a process unit of a refinery through the optimization of Heat
Exchanger Networks (HENs) by Pinch Analysis.
3. Understanding utility requirement through Graphical approach, hot and cold composite curve, Grand
Composite Curve (GCC), Cascade Diagram.
4. To propose a better HEN design and study its impact on the process economy.

Summary of Literature:
Optimization of use of energy (Heat) in particular of process is extremely important for economic viability and
Operation of a chemical Process.

Two Methodologies:

Mixed Integer Non-Linear optimisation Problem (MINLP) (Biegler et al., 1997). [Provides very limited
information about the factors that determine the minimum energy consumption of a process.]

Pinch Method which is based on a thermodynamic analysis of the process. (Linnhoff and Hindmarsh,
1983; Smith, 2005).
The core elements of Pinch Technology is the calculation of energy and cost targets for the process, which
inform the minimum energy consumption and the minimum cost of the HEN required to reach these targets,
based on the use of simplified graphical representations of the thermodynamic analysis.

The first application of these design techniques involved the conservation of energy through the optimization
of heat exchanger networks. This led to the development of Pinch Analysis as applied to energy conservation.
Linnhoff et al. (1994) used a graphical approach in which a heat exchange system is represented by a plot of
temperature as a function of enthalpy. A hot composite curve is made up of the streams which require cooling
and a cold composite curve is made up of the streams which require heating.
The point at which these curves come in the closest contact is the point at which there is a minimum heat
transfer driving force, known as the pinch point. This point is used to determine the minimum process
requirement and the optimal network design.

Figure 1 Composite curves in thermal pinch analysis

Pinch analysis was initially developed for the optimization of heat exchanger networks following the
methodology proposed by Linnhoff and Flower (1978). In this paper the problem of synthesizing optimal heat
exchanger networks was approached in two stages. In the first stage the heat exchange opportunities were
assessed within temperature intervals. The problem was divided into several sub networks from which the
overall heat exchange network was generated. The second stage involved an approach in which a chosen
minimum temperature approach (Tmin) between the hot and the cold streams based on practical
implications. A zero Tmin set an ideal uppermost bound in energy recovery.

The role of Tmin and the effect of the pinch point in the design of energy recovery networks was further
demonstrated by Linnhoff, Mason and Wardle (1979) where this methodology was applied to practical
problems. This describes the optimum use of utilities, the determination of the minimum number of process
units, the effect of stream splitting and cyclic networks, practical problem constraints as well as data
modification.

Linnhoff and Hindmarsh (1983) described the design method based on the location of the pinch point. This
method entails splitting the problem into two regions, above the pinch and below the pinch.

Materials & Methodology:

Hint (Heat Integration) Software

1. The software HINT was developed by Angel Martin in University of Valladolid, Spain.
2. A free educational software for heat exchanger network design based on the pinch method.
3. The program helps in
1. Energy and cost targeting,
2. Utilities selection,
3. Heat exchanger network specification,
4. Optimization and retrofitting analysis.
4. The program is used in Number of universities for educational purposes.

Figure 3: Screenshot of HINT Software.

Methodology

Data Extraction includes extraction of stream data (Temp. and Flow rate) from heat and mass balance
and arranging them in a table.

Select Tmin and obtain Pinch temperature via Composite Curve(CC)

Heating and cooling utilities can be obtained by Grand Composite Curve (GCC).

Grid Diagrams are constructed for above and below the pinch point respectively with
appropriate matching (keeping in mind the no. and CP (Kw/k) of the stream.

Heaters and Coolers are placed above and below the pinch point respectively and a final HEN can be
obtained.

Final part is the design of the exchangers and analyzing the economics of the design.

Construction Of
Collection of Formulation of
Composite
Process Data. Problem Tables.
Curves

Evaluations of Design of Heat

Grid Diagram
Economics and Exchanger
Representation
Utility Network

Work Done:
Problem Statement:

To calculate the hot and cold composite curves, Problem table, GCC, hot and cold utility target and pinch
temperature for the following the data given as, using HINT

STREAM SUPPLY TEMP (K) TARGET TEMP (K) CP(kW/K)

1 764.15 313.15 73.218

2 372.15 313.15 46.5089
3 466.15 313.15 21.5825
4 313.5 774.15 69.84
5 462.15 466.15 965.059
6 313.15 391.15 22.6582
DATA TAKEN

STREAM SUPPLY TEMP (K) TARGET TEMP (K) CP(kW/K) H(kW)

HOT I 764.15 313.15 73.218 -33021.3
HOT II 372.15 313.15 46.5089 -2833.55
HOT III 466.15 313.15 21.5825 -3302.13
COLD I 313.5 774.15 69.84 30799.8
COLD II 462.15 466.15 965.059 3860.24
COLD III 313.15 391.15 22.6582 1767.34
Solution:-

COMPOSITE CURVE

ASSUMPTION

1. Taking Tmin = 10K.

Temperatures of hot streams are shifted above by Tmin/2 i.e. 5K and that of cold streams are shifter
below by Tmin/2 i.e. 5K.
SHIFTED TEMPERATURES:

STREAM SUPPLY TEMP (K) TARGET TEMP (K)

HOT I 759.15 308.15
HOT II 367.15 308.15
HOT III 461.15 308.15
COLD I 318.5 779.15
COLD II 467.15 471.15
COLD III 318.15 396.15

STREAMS AND TEMPERATURE INTERVALS

HEAT CASCADE
GRAND COMPOSITE CURVE

From above curve and heat cascade we get:

Hot Utility (HU) = 4720.66 kW

Cold Utility (CU) = 5514.31 kW

Pinch Temperature = 467.15 K

Hot Pinch Temperature = 472.15 K

Cold Pinch Temperature = 462.15 K

Time-Line:
Month-wise Activities scheduled:

Month Activities performed

November17 Dec17 Detailed understanding of Hint software.
Study of the Case Study.
Procurement of Industrial Data.
January18- March18 Manual and software based calculations using
pinch technology.
Setup of Heat Exchanger Network and Utilities.
Proposing a new optimized PFD.
Submission of Final Report.

References:

Kemp, I.C. (2006). Pinch Analysis and Process Integration: A User Guide on Process Integration for the
Efficient Use of Energy.
Linnhoff, B., Townsend, D. W., Boland, D., Hewitt, G. F., Thomas, B. E. A., Guy, A. R. and Marsland, R. H.
(1982). User Guide on Process Integration for the Efficient Use of Energy, 1st edition. IChemE, Rugby, UK.
Revised 1st edition 1994.
Smith, R. (2005). Chemical Process Design and Integration. John Wiley, Chichester and New York.
Linhoff B., Flower J.R. 1978 Synthesis of heat exchanger networks, Part 1: Systematic generation of energy
optimal networks.
Linhoff B., Townsend D.W. 1983 Heat and power networks in process design. Part I: Criteria for the
placement of heat engines and heat pumps in process networks. Part II: Design procedure for equipment
selection and process matching. AIChe Jl. 29(5): 742-771
Linnhoff B., Townsend D.W., Boland D., Hewitt G.F., Thomas B.E.A., Guy A.R., Marsland R.H.1994 User
Guide on process integration for the efficient use of energy, IChemE. Rugby, UK.
Linnhoff, B., Pinch analysis A state-of-the-art overview. Trans IchemE, Vol. 71, Part A, September (1993).
Papalexandri, K. P., Pistikopoulos, E. N., A Multiperiod MINLP Model For Improving the Flexibility of Heat
Exchanger Networks. Annals of the European Symposium on Computer Aided Process Engineering (1993).
Papalexandri, K. P., Pistikopoulos, E. N., A multiperiod MINLP model for synthesis of flexible heat and mass
exchanger networks. Comput. Chem. Eng., Vol. 18, No 11/12, pp. 1125 (1994).
Smith, R. (2005). Chemical Process Design and Integration. John Wiley, Chichester and New York.