Pinch Point Technology - examples of application

Marcin Liszka, PhD Institute of Thermal Technology Silesian University of Technology Gliwice, Poland

Dipartimento di Energetica "Sergio Stecco"- Universit di Firenze, March 2, 2009

1

Example 1

Case study:

& = 0.4kW/K C 1
& = 0.5kW/K C 2

& 3 = 0.3kW/K C
& = 0.65kW/K C 4

Temperature 0C
2

Hot composite curve

o Tg1w = 30 oC Tg1w = 80 C

Tg 2 d = 220 oC Tg1d = 280 oC

hot stream no. 1 hot stream no. 2

Enthalpy change, kW
3

Cold composite curve

Enthalpy change, kW

cold stream no. 4

cold stream no. 3

Composite curves
o Tg1w = 30 oC Tg1w = 80 C

Tg 2 d = 220 oC Tg1d = 280 oC

hot stream no. 1 hot stream no. 2

Hot utility

& = 75kW Q r

& hu = 73kW Q

&

Cold utility

cold stream no. 4

& cu = 100kW Q
5

cold stream no. 3

Composite curves
o Tg1w = 30 oC Tg1w = 80 C

Tg 2 d = 220 oC Tg1d = 280 oC

hot stream no. 1 Hot utility

hot stream no. 2

& = 133kW Q r

& hu = 13kW Q

&
cold stream no. 4

& cu = 40kW Q
Cold utility
6

cold stream no. 3

Composite curves
25 126
Tmin =76.67K

280 260
o

24 pinch

220
C T

196.67 120 80
a r u t e p m

30
Cold utility

85.5
Heat recovery

32.5
Hot utility

30 20

100 Enthalpy change, kW

75

73

& I

Composite curves
25 126 pinch
Tmin=10K

280 260 220 210 130 120 80

a r u t e p m

24

30
Cold utility

85.5
Heat recovery

32.5
Hot utility

30 20

40
Enthalpy change, kW

13
& & I

Grand composite curve for assumed pinch=10K

5K pinch/2=5K

& = 0.4kW/K C 1
& = 0.5kW/K 5K C 2

5K

& = 0.3kW/K C 3 & = 0.65kW/K C 4

Temperature 0C
9

Grand composite curve for assumed pinch=10K

5K pinch/2=5K

& = 0.4kW/K C 1
& = 0.5kW/K 5K C 2

5K

& = 0.3kW/K C 3 & = 0.65kW/K C 4

Temperature 0C
10

Grand composite curve for assumed pinch=10K

5K pinch/2=5K

& = 0.4kW/K C 1
& = 0.5kW/K 5K C 2

5K

& = 0.3kW/K C 3
5K 5K 5K

& = 0.65kW/K C 4
5K

Temperature 0C
11

Grand composite curve for assumed pinch=10K

5K pinch/2=5K

& = 0.4kW/K C 1
& = 0.5kW/K 5K C 2

5K

& = 0.3kW/K C 3
5K 5K 5K

& = 0.65kW/K C 4
5K

Temperature 0C
12

Grand composite curve

& = 0.4kW/K C 1
& = 0.5kW/K C 2

& = 0.3kW/K C 3 & = 0.65kW/K C 4

25

75

125

215

265 275

Temperature 0C
13

Grand composite curve

& = 0.4kW/K C 1
& = 0.5kW/K C 2

& = 0.3kW/K C 3 & = 0.65kW/K C 4

V
25 75

IV
125

III
215

II

265 275

Temperature 0C
14

Grand composite curve

& C & C z z g g

& = 0.4kW/K C 1 & = 0.5kW/K C 2

& = 0.3kW/K C 3

Ti
10 50 90 50 50

& Q i
-4 12.5 4.5 -30 -10

j=1

& Q j

I II
II I

-0.40 +0.25 +0.05 -0.60 -0.20

-4 8.5 13 -17 -27

& = 0.65kW/K C 4

V
25 75

IV
125

III
215

III IV V

265 275

Temperature 0C

15

Grand composite curve

& j=1Q j
i

T
275oC

T
-8.5
275oC

& Q j j=1
-4

I
265oC

-4
265oC

II
215oC

8.5
215oC

II III
125oC

0 4.5 -25.5 -35.5

III
125oC

13 -17
75oC

IV
75oC

IV V
25oC

V
25oC

-27

16

Grand composite curve

& j=1Q j
i

T
275oC

T
-8.5
275oC

& Q j j=1
-4

I
265oC

-4
265oC

II
215oC

0 4.5

-4.5

II
215oC

0 0 -30 -40
130oC

III
125oC

III
125oC

pinch 10K
120oC

IV
75oC

-25.5
75oC

IV V
25oC

V
25oC

-35.5

17

Grand composite curve

& j=1Q j
i

T
275oC

-13

T
275oC

& Q j j=1

-13

I
265oC

-4
265oC

-17 -4.5 0 -30 -40

130oC

II
215oC

8.5
215oC

II III
125oC

III
125oC

13 -17
75oC

pinch 10K
120oC

IV
75oC

IV V
25oC

V
25oC

-27

18

Grand composite curve

Single hot utility & hu min = 13 kW Q 300
250

Temperature, C

200 150
125

100 50 0 0 10 20 30 40 Enthalpy change, kW

& cu min = 40 kW Q

19

Grand composite curve

Multiple hot utilities reduction of exergy losses
300
& hu 1 = 8.5 kW Q

250

Temperature, C

200 150
125

& hu 2 = 4.5 kW Q

100 50 0 0 10 20 30 40 Enthalpy change, kW

& cu min = 40 kW Q

20

Example 2
Optimization of Heat Recovery Steam Generators - single pressure no need for pinch analysis
zCO2= 0.088 zH2O= 0.05 zN2= 0.713 zO2= 0.138 mfg= 519.3 Tfg= 540.5 m21=73.61 T21= 420 p 21= 38 m24=22.5 dTmin= 15 m23=51.1 NmST1=17474

T tempearture [oC] p pressure [bar] m mass flow [kg/s] z molar fraction

NmST2= 36000

600 500 400 300

m11=73.61 200 T11=105.4 p 28= 1.2

Ts, Tfg [oC]

m32=6.421 Qus= 32000 m29=14.01 T33=39.01 p 33= 0.07

T10=178.6

100 p 11=38

T40=104.8

0
21

42

84 126 40 168 Heat transfer rate [MW]

=1.2

210

Example 2
Optimization of Heat Recovery Steam Generators - multi pressure - pinch analysis possible

Medium pressure loop (MP)

District heating

Low pressure loop (LP)

Mixing feed water preheater

22

Example 2
Optimization of Heat Recovery Steam Generators - component streams for cold composite curve
600

500

HP sh

Temperature [oC]

400

MP sh HP evap

300

MP evap

200

HP econ MP econ

100

LP econ
0 0 10000 20000 30000 40000

LP evap
50000 60000 70000 80000 90000 100000

Heat transfer rate [kW]

23

Example 2
Optimization of Heat Recovery Steam Generators - composite curves
600

Flue gas
500

HP sh HPsh +MPsh

Tem perature [oC]

400

MPsh +HPecon

300

HPecon +MPecon

200

HP evap MP evap LP econ

100

LP evap
0 0 50000 100000 150000 200000 250000 300000

Heat transfer rate [kW]

24

Example 3 Heat Exchanger Network Design

& = 2.0kW/K C 1
& = 3.0kW/K C 2
& = 4.0kW/K C 3
& = 1.5kW/K C 4

20

30

60

80

Temperature 0C
25

135 150 140

170

Heat Exchanger Network Design

Case study:
pinch 60oC 30oC 90oC

& , kW / K C
170oC 150oC

2 4

3.0 1.5

1 3
26

30oC 80oC

80oC

135oC 140oC

2.0 4.0

Heat Exchanger Network Design

Pinch method ensures maximal heat regeneration. The economic optimum could be however not at pinch method solution. The designs with smaller number of heat exchangers can be preferred economically.

27

Heat Exchanger Network Design Many final solutions are possible. Following advices should be considered to follow Pinch Method principles:
do not use hot utility below pinch as well as cold utility above pinch do not use extremely low and high temperature differences combine hot and cold streams of similar heat flux capacities maximize heat exchanger capacities temperature differences in heat exchangers should be equal or higher than at pinch point
28

Heat Exchanger Network Design Above the pinch point

combined streams should fulfill following relation:

& C & C g z
pinch
temperature temperature
T

Tmin

Tmin

h c n i p

pinch

G
p n i c h

t p e a m r u

& & & & Cg < C z

kW & I

& & > &C & C g z

kW & I

Enthalpy change

Enthalpy change

29

Heat Exchanger Network Design

Below the pinch point

combined streams should fulfill following relation:

& C & C g z

30

Heat Exchanger Network Design

pinch 60oC 30oC 90oC

& , kW / K C
170oC 150oC

2 4

3.0 1.5

e c r o g

1 3
31

30oC 80oC

80oC

135oC 140oC

2.0 4.0

Heat Exchanger Network Design

pinch 60oC 30oC 90oC

& , kW / K C
170oC 150oC

2 4

3.0 1.5

e c r o g

EI

1 3
32

30oC 80oC

80oC

135oC 140oC 240kW

2.0 4.0

Heat Exchanger Network Design

pinch 60oC 30oC 90oC

& , kW / K C
170oC 150oC

2 4

3.0 1.5

EII

EI 135oC HU 20kW 140oC 240kW

1 3
33

30oC 80oC

80oC 90kW

2.0 4.0

Heat Exchanger Network Design

pinch 60oC 30oC 90oC

& , kW / K C
170oC 150oC

2 4

3.0 1.5

EIII

EII 80oC 90kW

EI 135oC HU 20kW 140oC 240kW

1 3
34

30oC 80oC 90kW

2.0 4.0

Heat Exchanger Network Design

The network with maximal heat regeneration

pinch 60oC 30oC 90oC

& , kW / K C
170oC 150oC

2 4

3.0 1.5

CU EIII

1 3

60kW EIV 30oC 80oC

EII 80oC 90kW

EI 135oC HU 20kW 140oC 240kW

2.0 4.0

30kW 90kW

The operating cost is minimized but the capital cost may be not.
35

Heat Exchanger Network Design

Two heat exchangers can be reduced to one unit.

Tgw
EI

loop

Tgd
EII

Tzd

&I Q

& & II Q

Tzw Tgd

Tgw
EI*

Tzd
36

& I+ Q & II Q

Tzw

Heat Exchanger Network Design

pinch 60oC 30oC 90oC

& , kW / K C
170oC 150oC

2 4

3.0 1.5

CU EIII

1 3
37

60kW EIV 30oC 80oC

loop
80oC

EII 90kW

EI 135oC HU 20kW 140oC 240kW

2.0 4.0

30kW 90kW

Heat Exchanger Network Design

Tmin decreased by 5K.

- higher heat exchange area but still maximal heat recovery
60oC 30oC pinch

& , kW / K C
170oC 150oC

2 4

3.0 1.5

CU EIII

70oC

60kW EII* 65oC 90kW 120kW EI 135oC HU 20kW 140oC 240kW

38

1 3

30oC 80oC

2.0 4.0

Heat Exchanger Network Design

60oC 30oC

path
CU EIII

pinch

& , kW / K C
170oC

2 4

3.0 1.5

70oC

150oC

60+x kW EIi* 65oC 90kW 120-xkW EI 135oC HU 20+x kW 140oC 240kW

39

1 3

30oC 80oC

2.0 4.0

Heat Exchanger Network Design

Tmin again 10K.

60oC 30oC

path
CU EIII

pinch

& , kW / K C
170oC

2 4

3.0 1.5

75oC

150oC

67.5kW EII* 65oC 90kW 112.5kW EI 135oC

HU

1 3
40

30oC 80oC

2.0 4.0

27.5kW 140oC 240kW