Pinch Analysis:
Concepts
Prof. G.P. Rangaiah
Department of Chemical & Biomolecular
Engineering @ NUS
Dr. GP Rangaiah
Pinch Analysis Concepts - Outline
Overview
Energy Balance
Temperature-Enthalpy Diagram
Composite Curves
Problem Table Procedure
Pinch and its Significance
Grand Composite Curves
Heat Exchanger Network
o Grid Representation
o Design for Maximum Energy Recovery
Examples/Practice Session
Dr. GP Rangaiah 2
Overview
What is Pinch Analysis
A Set of Procedures for Heat Integration
• Simple, Based on Fundamental Principles, Systematic
Provides Targets and Heat Exchanger Networks
Developed since 1970’s onwards at ETH and Leeds
University by Bodo Linnhoff and co-workers
Extended to Other Areas
• Wastewater Minimization, H2 Management
Dr. GP Rangaiah 3
Example
Process Flowsheet
20oC 135oC
Heater
2 kW/oC
80oC 140oC
Heater Reactor
o
4 kW/ C
Stream Data 3 kW/oC 170oC
Cooler
Stream CP Supply Target
No. & (kW/K) (Initial) (Final)
60oC
Type TS (oC) TT (oC)
30oC 150oC
(1) Cold 2.0 20 135 Cooler Separator
1.5 kW/ oC
(2) Hot 3.0 170 60
(3) Cold 4.0 80 140
(4) Hot 1.5 150 30
Dr. GP Rangaiah 4
Energy Balance
Enthalpy Changes
Stream CP Supply Target Enthalpy Change
No. & (kW/K) (Initial) T, (Final) T, (Heat Load)
Type TS (oC) TT (oC) (kW)
(1) Cold 2.0 20 135 2(20 – 135) = – 230
(2) Hot 3.0 170 60 3(170 – 60) = + 330
(3) Cold 4.0 80 140 4(80 – 140) = – 240
(4) Hot 1.5 150 30 1.5(150-30) = + 180
Energy Balance
Net Heat Load = 330 + 180 – 230 – 240 = + 40 kW
Remove or Supply using a Cold or Hot Utility?
Feasible?
Dr. GP Rangaiah 5
Temperature-Enthalpy Diagram
Simple Example with 2 Process Streams
Stream Mass Specific Heat CP Supply T, Target T, Heat Load,
Type Flowrate Capacity, CP (kW/K) TS (oC) TT (oC) H (kW)
(kJ/kg.K)
Cold 0.25 4 1.0 20 200 - 180
Hot 0.4 4.5 1.8 150 50 + 180
Process
With Heat
Exchange
How much energy can be recovered?
Dr. GP Rangaiah 6
Temperature-Enthalpy Diagram
Heat Load or Enthalpy Change when a Process
Stream changes from Supply to Target Temperature
Q = H = CP (TS - TT)
assuming Constant Specific Heat
T/H Diagram for
Two Process Streams
Heat Recovery depends
on Minimum Temperature
Difference - How to find?
Dr. GP Rangaiah 7
Composite Curves
More than One Hot/Cold Stream
Stream CP TS TT Enthalpy
(kW/K) (oC) (oC) Change
(kW)
(2) Hot 3.0 170 60 + 330
(4) Hot 1.5 150 30 + 180
How to represent
2 hot streams
on a T/H Diagram?
Dr. GP Rangaiah 8
Composite Curves
More than One Hot Stream – Hot CC
Stream CP TS TT Enthalpy
(kW/K) (oC) (oC) Change
180
(kW) 170
160
(2) Hot 3.0 170 60 + 330 150
140
130
(4) Hot 1.5 150 30 + 180
Temperature (oC)
120
110
100
90
80
Temperature CP Enthalpy 70
60
Range (kW/K) Change (kW) 50
40
170 to 150 3.0 60 30
20
150 to 60 3.0 + 1.5 405 10
0
60 to 30 1.5 45 0 50 100 150 200 250 300 350 400 450 500 550 600
Heat Flow (kW)
Dr. GP Rangaiah 9
Composite Curves
More than One Cold Stream – Cold CC
Stream CP TS TT Enthalpy
(kW/K) (oC) (oC) Change 180
(kW) 170
160
(1) Cold 2.0 20 135 - 230 150
140
130
(3) Cold 4.0 80 140 - 240
Temperature (oC)
120
110
100
90
Temperature CP Enthalpy 80
70
Range (kW/K) Change (kW) 60
50
20 to 80 2.0 - 120 40
30
80 to 135 2.0 + 4.0 - 330 20
10
135 to 140 4.0 - 20 0
0 50 100 150 200 250 300 350 400 450 500 550 600
Heat Flow (kW)
Dr. GP Rangaiah 10
Composite Curves
Cold and Hot Composite Curves
Heating
Duty
(T)min
Heat Recovery
Region
Cooling
Duty
Dr. GP Rangaiah 11
Composite Curves
Targets from Heating
Duty =
Composite 20 kW
Curves
Tmin =
Tmin = 10oC 10oC
Hot Utility
= 20 kW Heat Recovery = 450 kW
Cold Utility
= 60 kW
Cooling
Duty =
60 kW
Pinch at
85 (or 90/80) oC
Dr. GP Rangaiah 12
Pinch and its Significance
Pinch Point: Driving force = Tmin
Red Dotted Region
Energy given by hot
streams from 170oC
Tmin = to pinch temperature
10oC (330 kW) + Hot
Blue Dotted Region Utility (20 kW) =
Energy required by
Energy given by hot
cold streams from
streams from pinch
pinch temperature to
temperature to 30oC
140oC (350 kW)
(180 kW) = Energy
required by cold
Red dotted region is
streams from 20oC
to pinch temperature in energy balance.
(120 kW) + Cold
Utility (60 kW)
Blue dotted region is Conclusion: there is NO heat flow across
in energy balance. (i.e., from above to below) the pinch point.
Dr. GP Rangaiah 13
Problem Table Procedure
Stream Temperature & Shifted Temperature
Stream No. CP TS TT
& Type (kW/K) (oC) (oC) Tmin = 10oC
(1) Cold 2.0 20 135
Stream T with
Shifted T in
(2) Hot 3.0 170 60
Brackets
(3) Cold 4.0 80 140
(4) Hot 1.5 150 30
Stream No. TS (oC) TT (oC)
& Type
(1) Cold 20 135
Shifted
(25) (140)
Temperature, T (2) Hot 170 60
(165) (55)
= Th - (½)Tmin
(3) Cold 80 140
= Tc + (½)Tmin (85) (145)
(4) Hot 150 30
(145) (25)
Dr. GP Rangaiah 14
Problem Table Procedure
Streams and Temperature Intervals
Stream CP TS TT (oC)
No./Type (kW/K) (oC)
(1) Cold 2.0 20 135
(25) (140)
(2) Hot 3.0 170 60
(165) (55)
(3) Cold 4.0 80 140
(85) (145)
(4) Hot 1.5 150 30
(145) (25)
Tmin = 10oC
Shifted T
Dr. GP Rangaiah 15
Problem Table Procedure
Stream CP
Problem Table No. (kW/K)
(1) Cold 2.0
Shifted Interval Si - Si+1 CPhot - CPcold H Surplus
(2) Hot 3.0
T, Si (oC) No., i (oC) (kW/oC) (kW) or Deficit
(3) Cold 4.0
S1 = 165 (4) Hot 1.5
1 20 + 3.0 + 60 S
S2 = 145 How to take
2 5 + 0.5 + 2.5 S care of
S and D?
S3 = 140
3 55 - 1.5 - 82.5 D
S4 = 85
4 30 + 2.5 + 75 S
S5 = 55
5 30 - 0.5 - 15 D
S6 = 25
Dr. GP Rangaiah 16
Problem Table Procedure
Heat Cascade
Feasible
Negative Hot Utility = 20 kW
Heat Cold Utility = 60 kW
Cascade
Pinch at
Infeasible Heat Cascade = 0
Pinch Temperature:
85 (or 90/80) oC
Dr. GP Rangaiah 17
Problem Table Procedure
Problem Table including Heat Cascade
Shifted T, Interval Si - Si+1 CPhot - H Surplus Infeasible Feasible
Si (oC) No., i (oC) CPcold (kW/oC) (kW) or Deficit Cascade Cascade
S1 = 165 0 20
1 20 + 3.0 + 60 S
S2 = 145 60 80
2 5 + 0.5 + 2.5 S
S3 = 140 62.5 82.5
3 55 - 1.5 - 82.5 D
S4 = 85 - 20 0
4 30 + 2.5 + 75 S
S5 = 55 55 75
5 30 - 0.5 - 15 D
S6 = 25 40 60
Dr. GP Rangaiah 18
Grand Composite Curve
Heating
Duty =
Plot of Shifted 20 kW
Temperature versus
Net Heat Flow (Heat
Cascade)
Pinch
Net Heat Sink
Shifted T
= 85oC
Net Heat Source
Cooling Duty
= 60 kW
Useful for Choosing
Utility Level and
Quantity
Dr. GP Rangaiah 19
Pinch and its Significance
Pinch
Driving force is minimum
Divides the problem
•Above Pinch
•Below Pinch
Net Heat Sink
•Above Pinch
Net Heat Source
•Below Pinch
Dr. GP Rangaiah 20
Pinch and its Significance
+ 10
kW
+ 10
kW
Flow
+ 10
kW
Golden Rules
NO heat transfer across the pinch
NO cold utilities above the pinch
NO hot utilities below the pinch
Dr. GP Rangaiah 21
Pinch and its Significance
Simple and Effective Concepts
Targets
Pinch Point
More In, More Out
Flexibility: Problem Division
Trade-offs
•Energy Targets and Number of Exchangers
Dr. GP Rangaiah 22
Example
Process Flowsheet 20oC
Heater
135oC
Stream Data 2 kW/oC
80oC 140oC
Stream CP Supply Target Heater Reactor
o
No. & (kW/K) (Initial) (Final) 4 kW/ C
Type TS (oC) TT (oC) 3 kW/oC 170oC
(1) Cold 2.0 20 135
Cooler
(2) Hot 3.0 170 60
(3) Cold 4.0 80 140 60oC
30oC 150oC
(4) Hot 1.5 150 30 Cooler Separator
1.5 kW/ oC
Targets Found Tmin = 10oC
Will be used in
Hot Utility = 20 kW, Cold Utility = 60 kW Heat Exchanger
Pinch Temperature: 85oC (or 90/80oC) Network Design
Dr. GP Rangaiah 23
Heat Exchanger Network
Grid Representation of HEN
Initial Grid Diagram for the Four-stream Problem
Dr. GP Rangaiah 24
Heat Exchanger Network
Grid
Commonsense Network Design Representation
Step 1: Heat of HEN
Exchange
between S2 & S3
Step 0:
Useful
90
1 Quantities
110
2
180
1
240 Next
Step 2: Heat Step?
Exchange
Dr. GP Rangaiah
between S4 & S1
25
Heat Exchanger Network
Grid
Commonsense Network Design Representation
Step 1: Heat of HEN
Exchange Step 4:
between S2 & S3 Cooler
Step 0:
Useful
90
1 C Quantities
90
110
H 2
50 180
1
240
Step 3: Compare with
Step 2: Heat
Heater Min. HU = 20 kW
Exchange
between S4 & S1 Min. CU = 60 kW
Dr. GP Rangaiah 26
Heat Exchanger Network
Design for Maximum Energy Recovery (MER)
Minimum Utilities
Pinch and its Significance
Golden Rules
Pinch Point
Design Above Pinch
Design Below Pinch
Dr. GP Rangaiah 27
Heat Exchanger Network
Above Pinch
o No Cold Utilities
o Hot streams have to be cooled to the pinch point using
cold streams only
Below Pinch
o No Hot Utilities
o Cold streams have to be heated to the pinch point using
Hot streams only
Start Network Design
at the Pinch (Most Constrained Point)
Dr. GP Rangaiah 28
Heat Exchanger Network
Design for Maximum Energy Recovery
Feasibility of a pinch match
Feasibility of a pinch match
above pinch requires:
below pinch requires:
CPHot ≤ CPCold
CPHot ≥ CPCold
Dr. GP Rangaiah 29
Heat Exchanger Network
MER Design for the Example
Start with Grid Place Useful
Quantities:
Diagram
CP and H
CP Pinch at 90/80 H
S. No.
170 90 60
2 3.0 240/90
150 90 30 90/90
4 1.5
135 80 20
1 2.0 110/120
3 4.0 140 80 240/0
Dr. GP Rangaiah 30
Heat Exchanger Network
Design Above Pinch for MER
CP requirement: CPHot ≤ CPCold for a pinch match
Heuristic for Lower Capital Cost of HEN: Maximum Q on each HE
Match Match
2 1
CP Pinch at 90/80 H
S. No.
170 90 60
2 3.0 1 240/90
150 90 30 90/90
4 1.5 2
135 125 80 20
1 2.0 H 2 110/120
20 90
3 4.0 140
1
80 Next: Design 240/0
240
Below Pinch
Heater
Dr. GP Rangaiah 31
Heat Exchanger Network
Design Below Pinch for MER
CP requirement: CPHot ≥ CPCold for a pinch match
Heuristic for Lower Capital Cost of HEN: Maximum Q on each HE
Identify
Match Pinch
Pinch at 90/80
3 Match(es)
CP H
S. No.
170 90 60
2 3.0 1 3 240/90
Match 4:
150 90 70 30 90/90
4 1.5 2 4 C OK?
60
135 125 80 35 20
1 2.0 H 2 3 4 110/120
20 90 90 30
3 4.0 140 80 240/0
1
Cooler
240
Dr. GP Rangaiah 32
Heat Exchanger Network
Complete HEN for MER
CP Pinch at 90/80 H
S. No.
170 90 60
2 3.0 1 3 240/90
150 90 70 30 90/90
4 1.5 2 4 C
60
135 125 80 35 20
1 2.0 H 2 3 4 110/120
20 90 90 30
3 4.0 140 80 240/0
1
240
Compare with Targets:
Min. HU = 20 kW; Min. CU = 60 kW
Dr. GP Rangaiah 33
Heat Exchanger Network
20oC 135oC
Heater
2 kW/oC
80oC 140oC
Heater Reactor
4 kW/oC
3 kW/oC 170oC
Cooler
60oC
o o
30 C 150 C
Cooler Separator
o
1.5 kW/ C
HEN
Designed for
Process 20 35 80 125 135 Minimum
4 3 2 H Utilities
Flowsheet
S1 80 140
with Heaters
1 Reactor
and Coolers S3
S2 170
Process
1
Flowsheet with
HEN Designed for 90
Minimum Utilities 3
S4 60
30 70 90 150
C 4 2 Separator
Dr. GP Rangaiah 34
Heat Exchanger Network
Process Flowsheet with
90
HEN Designed for Minimum
90
Utilities
20 35 80 125 135
4 3 2 H
S1
70 60 90
80 140
1 Reactor
S3
S2 170
60
20oC
Heater
135oC 30 150
2 kW/oC
C Separator
80oC
Heater
140oC
Reactor
S4
o
4 kW/ C
3 kW/oC 170oC
Cooler
60oC
30oC 150oC
Cooler Separator
1.5 kW/ oC
Dr. GP Rangaiah 35
Supertargeting
Choice of Tmin
With increasing Tmin,
Utilities increase and
HE area decreases
[since Q = U A (T)LM]
Optimum Tmin
Dr. GP Rangaiah 36
Pinch Analysis Concepts - Summary
Overview
Energy Balance
Temperature-Enthalpy Diagram
Composite Curves
Problem Table Procedure
Pinch and its Significance
Grand Composite Curves
Heat Exchanger Network
o Grid Representation
o Design for Maximum Energy Recovery
Examples/Practice Session
Dr. GP Rangaiah 37
