Pinch Analysis:
Data and Targeting
Prof. G.P. Rangaiah
Department of Chemical & Biomolecular
Engineering @ NUS
Dr. GP Rangaiah
Data and Targeting - Outline
Data Extraction
Case Study: Organics Distillation Plant (ODP)
Threshold Problems
Multiple Utilities
Advanced Energy Targeting
Targeting Number of (HE) Units
Targeting Area
Supertargeting
Examples/Practice Session
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Data Extraction
Process Data
For a New Plant: from Design Data
For an Existing Plant: from Measured Data
•Mass Balances
•Heat Balances
•Measurement Errors
•Heat Losses
•Data Reconciliation
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Data Extraction
Stream Data Extraction
Hot and Cold Streams
•Streams with Change in T (Heat Load) but
without Composition Change
Stream Supply & Target Temperatures
Stream CP or heat load (H)
H = Cp(TS – TT)
= (hS – hT)
= CP (TS – TT)
: mass flow rate (kg/s); Cp: specific heat capacity (kJ/kg.K)
h: specific enthalpy (kJ/kg)
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Data Extraction
Heat Loads and Heat Capacities
Use Correct Data T
CP variation
•Cp is a function of T
CP = c0 + c1T + …
H = c0T + c1(T2/2) + …
•Phase Changes
H
Segment a stream into 2 or more streams
Safe-side Linearisation
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Data Extraction
Choosing Streams
How many streams in this process?
Are they hot or cold streams?
Which layout should be
considered?
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Case Study: ODP
Organics Distillation Plant
Stream Mass Specific Initial Final
Flow Rate Heat T (oC) T (oC)
(kg/s) (kJ/kg.K)
Crude Feed 10 2+0.005T 20 180
Dehydrate (9.67) 3.1 152 302
Bottoms 4 2.5 261 158
Middle Oil 5 2 199 70
Overheads ? ? 123 52
Light Oil 2.67 2 52 52 Dehydrate
Fresh Oil 2 2 20 45
Water 0.33 4.19 52 52
Note: Back calculated value is shown in brackets.
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Case Study: ODP
Data for Existing Heat Exchangers
Streams Exchanger Hot Cold LMTD Calculated Calculated
Area (m2) Stream T’s Stream (oC) Heat Load Overall HTC, U
(oC) T’s (oC) (kW) (kW/m2.K)
Crude Feed/ 57.5 123 to 112 20 to 60 77 880 0.2
Overheads
Crude Feed/ 73.2 199 to 123 60 to (92) 83 760 0.125
Middle Oil
Note: T in brackets is calculated from energy balance on the HE.
o Assume all organic liquids have the same film HTC, and neglect
wall resistance.
o From U = 0.125 for Crude Feed/Middle Oil HE, h for organic liquids
is 0.25 kW/(m2.K)
o From U = 0.20 for Crude Feed/Overheads HE, h for overheads is 1.0
kW/(m2.K) – How? Ok?
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Heat Exchanger Basics
Heat Transfer Coefficients
Overall Heat Transfer Coefficient, U
• Film Heat Transfer Coefficient, h
Tube Bundle and
• Fouling Factor, Rd Tube Cross-section
• Wall Resistance (Small)
hi, Rdi
ho, Rdo
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Case Study: ODP
Process Stream Data
o Using calculated heat load of 880
kW for Cold feed-Overheads
exchanger, CP of Overheads from
𝟖𝟖𝟎
123 to 112 C =
o = 80 kW/K
(𝟏𝟐𝟑 𝟏𝟏𝟐)
o From cooling water flow rate and
temperatures of Overheads cooler,
its heat load is 1,800 kW
o CP (for Overheads from 112 to
𝟏,𝟖𝟎𝟎
52oC) = = 30 kW/K
(𝟏𝟏𝟐 𝟓𝟐)
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Case Study: ODP
Process Stream Data
Stream Stream TS (oC) TT (oC) Film HTC CP (kW/K) Heat Flow Rate
Name Type (kW/m2.K) (kW)
Bottoms Hot 1 261 158 0.25 10 1,030
Middle Oil Hot 2 199 70 0.25 10 1,290
Overheads Hot 3A 123 112 1 80 880
Overheads Hot 3B 112 52 1 30 1,800
Crude Feed Cold 1 20 180 0.25 20+0.05T -4,000
Dehydrate Cold 2 152 302 0.25 30 -4,500
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Energy Targeting
Use Problem Table Procedure or Composite
Curves to find Minimum Utilities, Pinch Point and
Grand Composite Curve for a given Tmin
Tmin may have to be different for some streams
due to their HTC
Include this as individual Tmin contribution
Shifted T = T (½) Tcont instead of T (½) Tmin
No Other Change in Problem Table Procedure
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Energy Targeting
Case Study: ODP
Assume Tmin = 20oC
CP of Crude Feed = 2 + 0.005 T kJ/(kg-K)
Segment Crude Feed into 2 Streams
Stream Stream TS (oC) TT (oC) Film HTC CP (kW/K) Heat Flow Rate
Name Type (kW/m2.K) (kW)
Bottoms Hot 1 261 158 0.25 10 1,030
Middle Oil Hot 2 199 70 0.25 10 1,290
Overheads Hot 3A 123 112 1 80 880
Overheads Hot 3B 112 52 1 30 1,800
Crude Feed Cold 1A 20 103 0.25 23.075 -1,915
Crude Feed Cold 1B 103 180 0.25 27.075 -2,085
Dehydrate Cold 2 152 302 0.25 30 -4,500
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Energy Targeting
Case Study: ODP
Using Available Software
Hot Utility = 4,795 kW
Cold Utility = 1,295 kW
Pinch at 113oC (123/103oC)
Comparison
Dehydrate
Situation Tmin HU CU Heat Exchanger
(oC) (kW) (kW) Recovery Area (m2)
(kW)
Current 63 6,860 3,360 1,640 128.5
Target 63 5,830 2,330 2,670 225.4
Target 20 4,795 1,295 3,705 605.0
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Energy Targeting
Case Study: ODP
Composite Curves
Grand Composite Curve
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Threshold Problems
Many Processes need
both HU and CU
Pinch Problems
Many Others need
either HU or CU
Threshold Problems
No Pinch
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Threshold Problems
Two Types of Threshold Problems
Which utility is
required?
Temperature approach
closest at the “non-
utility” end. Mostly
large driving forces.
Which utility is
required?
Near pinch, and
smaller driving forces
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Multiple Utilities
Hot Utilities
LP, MP and HP Steam
Furnaces
Flue Gas Constant-Temperature
Utility
Electric Heating
Cold Utilities
Steam Production Variable-Temperature
Cooling Water Utility
Air Cooling
Chilled Water
Refrigeration Systems
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Multiple Utilities
Appropriate Placement Principle
Above the Pinch: Hot Utilities ONLY
Below the Pinch: Cold Utilities ONLY
Which Utility? How many Utilities?
Cheaper
One or more
Use GCC
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Multiple Utilities
Case Study: ODP
Steam at 330oC
- How Much?
Grand
Composite
Curve
4.8 MW from
Furnace or
Steam at Shifted T of
Steam at 330oC
200oC. How Much?
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Multiple Utilities
Pocket: Heat
Exchange among
4-Stream Example Process Streams
GCC
(Continuous lines)
Pinch
Shifted T
Heating duty (= 20 kW) = 85oC
at what temperature?
Cooling duty (= 60 kW)
at what temperature?
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Multiple Utilities
Two Hot Utilities
Utility Pinch
Whenever a utility profile
touches GCC
Increases number of units
GCC
(Continuous
(discussed later) lines)
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Multiple Utilities
Variable-temperature Utility
GCC for ODP Case Study
Shifted T (oC)
Flue gas at Shifted T = 360oC
and CP = 24 kW/K
GCC
(Continuous
Improvement: Decrease lines)
CP or Shifted T
Utility Pinch?
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Advanced Energy Targeting
Zonal Targeting
Targeting for the Complete Plant
• Good Idea. But is heat exchange between two parts of a
plant feasible? Any operational problems?
Targeting for Individual Parts of a Plant
Assess Benefits of HEN for the Complete Plant
versus HEN for Individual Parts of a Plant
• Consider HEN for the complete plant if the benefits are
significant
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Advanced Energy Targeting
Case Study: ODP
Down-stream Plant: Vacuum Distillation Unit
VDU:
One Cold Stream
One Hot Stream
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Advanced Energy Targeting
Case Study: ODP
Energy Targeting Separately and Together
Situation Current HU Potential CU Pinch –
HU use Target HU Saving Target Shifted
(kW) (kW) (%) (kW) T (oC)
Atmospheric Unit 6,860 4,795 30.1% 1,295 113
VDU 1,640 1,640 0.0% 1,050 140-165
Separately 8,500 6,435 24.3% 2,345 -
Combined Plant 8,500 6,085 28.4% 1,995 113
Significant Savings by HEN GCC for the
for the Combined Plant? Combined
Plant
Network Design Easy?
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Advanced Energy Targeting
Pressure Drop
HEN may increase
•Pump Power and/or
•Number of Pumps
(Source: wikipedia.org)
Important in both Design and Retrofitting
Pressure Drop Targeting
•Along with Other Targeting
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Targeting Number of (HE) Units
Streams and their Energy in a Process
Hot Utility/Stream
and their Energy
(Total = 3638) Energy
Balance
Satisfied
Cold Utility/Streams
and their Energy
(Total = 3638)
How Many Units
(Exchangers,
Heaters and
Coolers)?
Minimum Number of Units,
Umin = Total Number of Streams (N) - 1
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Targeting Number of Units
Another Example How many units?
Possible to
decrease?
4 Units
“Subset Equality”
Umin = N – s
(s = number of subsets)
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Targeting Number of Units
Umin for MER Design
Pinch, Two Sub-problems
Above Pinch and Below Pinch
Umin, MER = Umin, a + Umin, b
Umin without Pinch (Subdivision)
Umin Umin, MER
Scope to Reduce Units by Sacrificing Some
Energy Recovery (Network Relaxation)
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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
Hot Utility = 20 kW, Cold Utility = 60 kW Will be used in
the following …
Pinch Temperature: 85 (or 90/80) oC
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Targeting Number of Units
Four-Stream Example (No Pinch)
H
330
180
230
240
HU CU
Umin = N – 1
= (4+1+1) – 1 = 5
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Targeting Number of Units
Four-Stream Example (with Pinch for MER)
CP Pinch at 90/80 H
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
Umin, a = (4+1) – 2 = 3 (2 sub-sets)
Umin, b = (3+1) – 1 = 3
Umin, MER = Umin, a + Umin, b = 6
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Targeting Number of Units
Four-Stream Example (with Pinch for MER)
CP Pinch at 90/80 H
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
Design using the minimum Improvement
utilities and corresponding Possible?
target number of units
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Targeting Area
Using Composite
Curves
Divide CCs into Segments
Segment: No change in
Streams or Utilities in a
segment
Calculate Area for Each
Segment
How many segments for
the 4-stream example?
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Targeting Area
5
6
Cooling Water
from 20 to 45oC
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Targeting Area
1
Segment 1
Cold stream, C3 (CP = 4 kW/K) is
heated from 135 to 140oC. 3
Assume steam at 180oC is used for 2
this.
Assume hC3 = 0.4 and hSTM = 1.0
kW/m2K
U 1/(1/0.4 + 1/1.0) = 0.286 kW/m2K 4
(T)LM =
𝟏𝟖𝟎 𝟏𝟒𝟎
𝐥𝐧
(𝟏𝟖𝟎 𝟏𝟑𝟓)
𝟏𝟖𝟎 𝟏𝟒𝟎 = 42.45oC
𝟏𝟖𝟎 𝟏𝟑𝟓
From Q = U A (T)LM,
Stream No. CP Supply Target HTC, h
A = Q / {U(T)LM} & Type (kW/K) TS (oC) TT (oC) (kW/m2K)
= 4x(140-135) / (0.286x42.45) (1) Cold 2.0 20 135 0.2
(2) Hot 3.0 170 60 0.1
= 1.65 m2
(3) Cold 4.0 80 140 0.4
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Targeting Area
Segment 3
3
Hot streams 2 and 4 are cooled from
150 to 90oC
Cold streams1 and 3 are heated from
80 to 125oC
[ = 80 + (3.0+1.5)x(150-90) / (2.0+4.0)]
(T)LM = 𝟏𝟓𝟎 𝟏𝟐𝟓 = 16.4oC Stream No. CP Supply Target HTC, h
𝟗𝟎 𝟖𝟎
& Type (kW/K) TS (oC) TT (oC) (kW/m2K)
(1) Cold 2.0 20 135 0.2
(2) Hot 3.0 170 60 0.1
(3) Cold 4.0 80 140 0.4
(4) Hot 1.5 150 30 0.3
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Targeting Area
Segment 3
3
For a 2-stream HE, Area, A =
𝐋𝐌 𝐋𝐌 𝐡 𝒄
For Multiple Streams in a Segment,
𝒉𝒊 𝒄𝒋
A=
𝐋𝐌 𝐡𝐢 𝐜𝒋
Stream No. CP Supply Target HTC, h
= & Type (kW/K) TS (oC) TT (oC) (kW/m2K)
(1) Cold 2.0 20 135 0.2
(2) Hot 3.0 170 60 0.1
= 182.9 m2 (3) Cold 4.0 80 140 0.4
(4) Hot 1.5 150 30 0.3
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Targeting Area
Total Area = Sum of Areas for All Segments
Target for MER Network before Network Design
Assumptions
Counter-Current flow
Vertical Matching (but Criss-
Crossing may be Better)
Area accurate to within ±10%
Sufficient for Capital Cost
Estimation
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Supertargeting
Decreasing Tmin leads to
Lower HU and CU, and so Lower OC
Smaller Heaters/Coolers, and so Lower CC
Lower Driving Forces, and Greater Heat Exchange
Larger Exchangers and Higher CC
Supertargeting: Finding Optimal Tmin
OC and CC are calculated using Targets for Energy,
Number of Units and Area at each of Many Tmin Values
Assumption: Same Area for Each Unit
HEN Design is NOT required
Can be Automated Easily
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Supertargeting
Choice of Tmin
With increasing Tmin,
Utilities increase and
HE area decreases
[since Q = U A (T)LM]
Optimum Tmin
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Supertargeting
Case Study: ODP
Flat Curve: Optimum
Tmin is not Sharp
Optimum Tmin is not
much affected by
approximations in HTC
and Area Estimate
Variation of Capital Cost, Operating
Cost and Total Cost with Tmin
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Data and Targeting - Summary
Data Extraction
Case Study: Organics Distillation Plant (ODP)
Threshold Problems
Multiple Utilities
Advanced Energy Targeting
Targeting Number of (HE) Units
Targeting Area
Supertargeting
Examples/Practice Session
Dr. GP Rangaiah 44
