Pinch Technology Part I

INTRODUCTION TO PINCH TECHNOLOGY
OCTOBER 2004
PART I

PART I
ENGINEERING TRAINING SESSION
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INTRODUCTION TO PINCH TECHNOLOGY Page 1
PINCH TECHNOLOGY
PART I
z INTRODUCTION
z COMPOSITE CURVES
z GRAND COMPOSITE CURVES
z NETWORK DESIGN
PART II
z PINCH TOOLS
z DATA EXTRACTION
z PROCESS MODIFICATIONS
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OCTOBER 2004
PART I
INTRODUCTION
Introductory Quiz
z What Is Pinch Technology?
A. A methodology to help assess process options.
B. A methodology to optimize an existing design.
C. A means to impress customers and colleagues.
D. All of the above (depending who you hang with).
z What Good Is Pinch Technology?
A. It helps minimize energy requirements.
B. It helps minimize capital costs.
C. It helps minimize the number of heat exchangers (or shells).
D. It helps minimize annualized costs.
E. It provides a warm fuzzy feeling that the process is reasonably well
designed.
F. All of the above (depending).
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INTRODUCTION
How much does a 106 Btu/h cost?
Utility Unit Cost Annual Energy Cost*

$/yr/106 Btu/h
HP Saturated Steam - 600# $3.51 /1000 lb 38,550
MP Saturated Steam - 100# $2.29 /1000 lb 21,357
LP Saturated Steam - 50# $1.53 /1000 lb 13,423
Electricity $0.05 /kWh 117,200
Fuel Gas $3.00 /106 Btu 24,000
* Assuming 8000 operating hours per year.
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OCTOBER 2004
PART I
INTRODUCTION
Consider a single heat exchanger.
T2
t1 t2
Cold Stream
Hot Stream T1
Q = U*A*Tlm, A = Q/(U*Tlm)
Q = [M*Cp]hot*T = [M*Cp]cold*t
Look at the heating and cooling curves.
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INTRODUCTION
T1
Tmin
t2 Constant MCp
TEMPERATURE
Slope = 1/MCp
T2
Steepest slope =
smallest heat capacity
3 Shells in Series flowrate
t1
Q
DUTY
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OCTOBER 2004
PART I
INTRODUCTION
If T2 (hot outlet) < t2 (cold outlet)

z Temperature Cross
z Multiple shells may be needed
If [MCp]hot > [MCp]cold
z Minimum temperature approach is at the hot end.
If [MCp]hot < [MCp]cold
z Minimum temperature approach is at the cold end.
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INTRODUCTION
What happens if one increases the temperature driving force?
z Shift cold curve to the right.
z Tlm increases.
z Tmin increases.
z Area decreases.
z Less heat is recovered.
T1
Tmin
t2
TEMPERATURE
Tmin
T2
Q
t1
Q
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OCTOBER 2004
PART I
INTRODUCTION
What about phase change?

z Break up in segments.
z Calculate the area for each segment.
) A = Ai = Qi/(Ui*Tlm)
Temperature
Tlm3
Tlm2
Tlm1
Q1 Q2 Q3
uop Duty
INTRODUCTION
Consider a simple system.
T1
Hot Stream
Steam
t1 t2 t3
Cold Stream
T2
T3
CW
How would one determine the optimal values for T2 and t2?
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OCTOBER 2004
PART I
INTRODUCTION
Plot Temperature vs. Duty.
Qhot
t3
T1
TEMPERATURE
Tmin t2
T2
T3
t1
Qcold Qrec
DUTY
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INTRODUCTION
What is the maximum possible heat recovered from the hot stream?
Qhot min
Tmin= 0 t3
T1
TEMPERATURE
t2
T2
T3
t1
Qcold min
Qrec max
DUTY
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OCTOBER 2004
PART I
INTRODUCTION
What happens as Tmin approaches 0?

z Hot utility (steam)consumption is the lowest.
z Cold utility (cooling water) consumption is the lowest.
How many exchangers are required?
z Three
) 1 process-process exchanger.
) 1 process-hot utility exchanger.
) 1 process-cold utility exchanger.
What is Tlm over the range Qrec?
z Very small.
How big is the hot to cold process heat exchanger?
z Very big.
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INTRODUCTION
How does Tmin affect the system?

z Utility requirements.
z Heat exchanger areas.
How would one find an optimum Tmin ?
z Design and cost the system for a range of Tmin .
) Determine capital costs.
) Determine operating costs.
z Combine capital and operating costs to determine an annualized
cost.
z Plot annualized cost vs. Tmin .
z Select the minimum.
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OCTOBER 2004
PART I
INTRODUCTION
Tm in OPTIMIZATION
140
120
100
Cost (10 $/y)
80
6
60
Tmin opt
40
20
0
0 10 20
T30
m in
40 50 60
Utility Costs Annualized Capital Cost Total Cost

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INTRODUCTION
Other factors to consider besides annualized cost.

z Number of exchangers (shells).
z Capital limitations.
z Utility limitations.
z Process limitations (i.e., pressure drop).
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OCTOBER 2004
PART I
INTRODUCTION
What about a slightly more complicated problem?
Stream MCp Tsupply Treqd Duty (Q)
H1 0.050 315 240 -3.75

H2 0.200 240 140 -20.00
C1 0.075 40 130 +6.75
C2 0.125 130 260 +16.25
Steam 350 350
CW 27 40
How many heat exchangers?

How much steam and cooling water is required?
How much do the heat exchangers cost?
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INTRODUCTION
Propose a solution. Maximum utilities.

Network Representation
Steam 350 350
H1 315 240
H2 240 140
6.75
C1 130 40
16.25
C2 260 130
20.0 3.75
CW 40 27
Steam Load = 23.00 CW Load = 23.75
uop Is this a good design?

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OCTOBER 2004
PART I
INTRODUCTION
Propose another solution.
Network Representation
Steam 350 12.50 350
H1 315 240
240 206 140

H2
6.75
C1 130 40
160 3.75
C2 260 130
13.25
CW 40 27
Steam Load = 12.50 CW Load = 13.25
uop Is this better?

INTRODUCTION
Did you notice that the difference between the steam and cooling
water duties remained constant?
z Why is this true?
Is there a better solution?
z Define better.
How may solutions are there?
z Infinite.
How would one determine the economic optimum?
z Same as for a single exchanger. Calculate annualized cost as a
function of Tmin.
z Need heat transfer coefficient (U) estimates.
z Need a cost correlation for heat exchanger area vs. cost.
How much time can we spend?
z Not much.
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OCTOBER 2004
PART I
INTRODUCTION
A SYSTEMATIC APPROACH IS NEEDED!
NEED TO MAKE SOME SIMPLIFYING ASSUMPTIONS
HOW ABOUT PINCH TECHNOLOGY?
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INTRODUCTION
Pinch Technology
z Calculate utility requirements.
z Estimate optimal exchanger requirements.
z Provide an overview of energy flow in the entire process/refinery.
z Obtain an overall view of the entire steam/power system on a
single page.
All this without designing any heat exchangers.
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OCTOBER 2004
PART I
INTRODUCTION
Benefits of Pinch Technology

z Optimize heat transfer while developing the process flow.
z Budget exchanger costs and utility requirements before designing
the heat exchange network.
z Evaluate how good a design is and the potential for improvement.
z Help establish operating conditions (e.g., column operating
pressures).
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COMPOSITE CURVES
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OCTOBER 2004
PART I
COMPOSITE CURVES
How does one handle multiple streams that have temperature

overlap?
Stream data needs to be combined in a way so as to represent the
energy sources and energy demands in each temperature range.
The pinch method creates what is called a composite curve.
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COMPOSITE CURVES
Multistage Reactor Example - Description
550 Rxtr
Feed
#1 510 A 550
Rxtr
#2 520
B 560
To Next Reactor
Streams A and B have overlapping duties between 520 and 550.
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OCTOBER 2004
PART I
COMPOSITE CURVES
Multistage Reactor Example - Stream Data
Range T in T out Streams M*Cp Q

1 510 520 A 1 10
2 520 550 A 1 30
520 550 B 1 30
520 550 A+B 2 60
3 550 560 B 1 10
Plot T vs. Q for each temperature range.
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COMPOSITE CURVES
Multistage Reactor Example - Composite Curve
570
560
TEMPERATURE (T)
550
540
530
520
510
500
0 20 40 60 80 100
Duty (Q)
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OCTOBER 2004
PART I
COMPOSITE CURVES
There is an easy way to plot the composite curves: just add up the
Q values over each range of T
570
560
TEMPERATURE (T)
550
540
530
520
510
500
0 20 40 60 80 100
Duty (Q)
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COMPOSITE CURVES
Class Exercise - Create Composite Curves for a Platforming Process
Reactors & Reheats Recycle Gas

Compressor
Net Gas
Off Gas
Light Ends
Fresh
Feed
Debutanizer
uop Platformate
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OCTOBER 2004
PART I
COMPOSITE CURVES
Class Exercise - Create Composite Curves for a Platformer

z Cold stream: combined feed: MCp= 0.25 x 106 Btu/h.F
) feed preheat Tin = 260F Tout = 980F
) 1st reheat Tin = 860F Tout = 980F
) 2nd reheat Tin = 920F Tout = 980F
) 3rd reheat Tin = 950F Tout = 980F
z Cold stream: column feed: MCp = 0.15 x 106 Btu/h.F
) Tin = 150F Tout = 300F
z Cold stream: debutanizer reboil: Q = 12 x 106 Btu/h
) reboil temperature = 400 F
z Hot stream: reactor product: MCp = 0.25 x 106 Btu/h.F
) Tin = 960F Tout = 150F
z Hot stream: product rundown: MCp = 0.15 x 106 Btu/h.F
) Tin = 400 F Tout = 150F
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Stream Data
Strm Tin Tout T MCp Q
1 260 980 720 0.25 180 cold

2 860 980 120 0.25 30 cold
3 920 980 60 0.25 15 cold
4 950 980 30 0.25 7.5 cold
5 150 300 150 0.15 22 cold
6 400 400 0 ?? 12 cold
7 960 150 -810 0.25 -202 hot
8 400 150 -250 0.15 -38 hot
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OCTOBER 2004
PART I
COMPOSITE CURVES
1000
800
600
400
200
0
0 50 100 150 200 250
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COMPOSITE CURVES
1000
800
600
400
200
0
0 50 100 150 200 250
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OCTOBER 2004
PART I
COMPOSITE CURVES
1000
800
600
400
200
0
0 50 100 150 200 250
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COMPOSITE CURVES
1000
800
600
400
200
0
0 50 100 150 200 250
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OCTOBER 2004
PART I
COMPOSITE CURVES
1000
800
600
400
200
0
0 50 100 150 200 250
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COMPOSITE CURVES
1000
800
600
400
200
0
0 50 100 150 200 250
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OCTOBER 2004
PART I
COMPOSITE CURVES
1000
800
600
400
200
0
0 50 100 150 200 250
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COMPOSITE CURVES
1000
800
600
400
200
0
0 50 100 150 200 250
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OCTOBER 2004
PART I
COMPOSITE CURVES
1000
800
600
400
200
0
0 50 100 150 200 250
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COMPOSITE CURVES
1000
800
600
400
200
0
0 50 100 150 200 250
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OCTOBER 2004
PART I
COMPOSITE CURVES
1000
800
600
400
200
0
0 50 100 150 200 250
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COMPOSITE CURVES
QH
1000
800
600 Pinch
400
200
QC
0
0 50 100 150 200 250
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OCTOBER 2004
PART I
COMPOSITE CURVES
QH
1000
800
600 Pinch
400
200
QC
0
0 50 100 150 200 250
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COMPOSITE CURVES
Suppose there are two hot streams and two cold streams.
Qhot
pinch
h1
TEMPERATURE
h1 & h2 c2
h2
c1 & c2
c1
Qcold Qrec
DUTY
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OCTOBER 2004
PART I
COMPOSITE CURVES
What is the minimum possible utility?
Qhot min
pinch
h1
TEMPERATURE
h1 & h2 c2
h2
Shift the cold
c1 & c2 curve to the left
until it touches
c1 the hot curve.
Qcold min
Qrec max
DUTY
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COMPOSITE CURVES
How many exchangers are required?

Above the pinch:
1 cold +2 hot
Steam
N-1 = 2
h1
TEMPERATURE
h1 & h2 c2 Below the pinch:

h2 3 cold +2 hot
c1 & c2 N-1 = 4
c1
CW 6 Exchangers
total.
DUTY
z Rule: N streams (hot&cold) need at least N-1 exchangers.
z Apply above and below the pinch.
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OCTOBER 2004
PART I
COMPOSITE CURVES
Increase Tmin. How many exchangers are now required?
Above the pinch:

Steam 2 cold +2 hot
h1 N-1 = 3
TEMPERATURE
h1 & h2 c2 Below the pinch:

h2 Tmin 3 cold +2 hot
c1 & c2 N-1 = 4
c1
CW 7 Exchangers
total.
DUTY
z Rule: N streams (hot&cold) need at least N-1 exchangers.
z Apply above and below the pinch.
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COMPOSITE CURVES
What happens as Tmin is increased?

z More heat exchangers are required. ($ Extra)
z Tlm s are greater.
) Each heat exchanger is smaller.
) The cost for each heat exchangers decreases. ($ Savings)
z More utilities are consumed.
) Cooling demand increases.
) Hot utility demand increases.
) Utility costs increase. ($ Extra)
) Note: hot utility increase = cold utility increase
How does one decide on the appropriate Tmin?
z Same as previously discussed.
z Plot Total Cost vs. Tmin .
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OCTOBER 2004
PART I
COMPOSITE CURVES
What is the optimum heat exchange arrangement?

z Vertical heat exchanger matching is ideal.
z Maximize the T driving force at all points.
Steam
h1
TEMPERATURE
h1 & h2 c2
h2
c1 & c2
c1
CW
DUTY
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COMPOSITE CURVES
What happens if we start doing heat exchange that is not vertical?

Steam
Qex cold
h1
TEMPERATURE
h1 & h2
c2
h2
Qex hot
c1 & c2
c1
CW
DUTY
then
z Qex hot must come from steam.
z Qex cold must go to cooling water.
uop z This is the same as using a larger Tmin from the start.
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OCTOBER 2004
PART I
COMPOSITE CURVES
Rule: Transferring heat across the pinch leads to

increased utilities.
below above Qex hot
pinch pinch Steam
Qex coldregion region
h1
TEMPERATURE
h1 & h2
c2
h2
c1 & c2 Qex hot

c1
CW
Qex cold
DUTY
z Qex has been transferred from above the pinch to below the pinch..
z This cascades to the cold end and affects the entire heat-recovery
uop system.
COMPOSITE CURVES
Guideline:
z Find the pinch.
z Transfer no heat across the pinch.
z Transfer heat as vertically as possible.
z T > Tmin for all heat exchangers.
z Start at the pinch and work outward.
) Above the pinch.
) Below the pinch.
) Treat as totally separate systems..
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OCTOBER 2004
PART I
COMPOSITE CURVES
Network representation:
Steam 250 C
200 C 150 C 150 C 60 C
H1
150 C 55C
H2
110 C 45C
C1
200C 135C 135C 75C C2
40 C 30C
CW
z C1 - does not reach the pinch. pinch
z C2 - goes through the pinch
z H1 - goes through the pinch
uop z H2 - starts at the pinch ---- H2 causes the pinch!
COMPOSITE CURVES
SUMMARY
z Obtain stream enthalpy - temperature data.
) Combine data for each temperature range.
z Create composite curves.
z Vary Tmin to determine optimum temperature approach.
) Determine utility loads and pinch temperatures.
z Use the pinch temperatures and composite curves to develop a
stream grid diagram.
) Find the correct pinch locations.
z Now is the time to design the network and the heat exchangers.
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OCTOBER 2004
PART I
COMPOSITE CURVES
What have we achieved?

z Estimated overall heat exchange needs.
) Area
) Number of exchangers
) Capital costs
z Optimized capital and operating costs.
) Determined the true minimum for given flows and temperatures.
z Estimated total utility requirements.
z All without designing any networks or heat exchangers.
Compare to the usual methods.
z Place important heat exchangers first, fill in gaps with utilities.
z Guess a network, and optimize by repeated simulation.
) Repeated numerical optimization.
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COMPOSITE CURVES
Contributions - a concession to practicality.

Approach varies with the type of utility?
z Steam: 5 - 10 C typical
z Cooling water: 15 - 20 C typical
z Air: ~30 C typical
Need a way to include this variation in the analysis
z Define a contribution.
z Here is how Advent defines the term:
Contribution = Tmin utility - Tmin global/2
Now Tmin global can be large while still allowing a reasonable

approach for utilities.
z e.g., Tmin global = 40 C, Tmin cw = 10 C, Contribution = -10 C
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OCTOBER 2004
PART I
GRAND COMPOSITE
CURVES
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GRAND COMPOSITE CURVES
Grand composite curves aid in selection and placement of utilities.

Consider the following:
QT1
T1
T2
TEMPERATURE
DUTY
Not all the heat has to be supplied at T1.

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OCTOBER 2004
PART I
Some heat can be supplied at T2.
QT1
T1
QT2
T2
TEMPERATURE
Note: QT1+ QT2 =

same as QT1
previously.
DUTY
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Intermediate utility placement can be cumbersome.

z Not too difficult for steam.
z How about hot oil with a varying temperature?
) Hard to distinguish from process streams.
z Need an easier way.
Grand Composite Curves
z Graphically shows the amount of utility required at any Tj.
) Horizontal distance between curves at Tj.
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OCTOBER 2004
PART I
Creating Grand Composite Curves

z Shift hot curve down by Tmin /2.
z Shift cold curve up by Tmin/2.
z The curves will touch at the pinch.
T Qh
T Qh
Qc Qc
Q Q
uop Note that Qh and Qc do not change.
z Plot Q separation (Q hot curve - Q cold curve)

) Plot range from Tcoldest T Thottest (see s)
) Note that at the pinch, Q = 0.
) Replace missing pieces with vertical dummy lines (see *s)
com posit e cu r ves gr a n d com posit e
(CC) (GCC)
Tsh ift
* Qh
** outside of
** temperature
overlap region
over la p
r egion H ea t Deficit
Region
H ea t Su r plu s
Region
**
* Qc
uop Q Q
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OCTOBER 2004
PART I
Now the potential for intermediate utility usage is clear.

z Take the required utility temperature and put on the same shifted
temperature scale.
) Adjust cold utility by +Tmin/2.
) Adjust hot utility by -Tmin/2.
z Locate Tshifted on the Grand Composite Curve (GCC).
z The maximum possible utility load pinches on the GCC.
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various steam levels

Tsh ift
H ea t Deficit
Region
H ea t Su r plu s
Region
cooling water
Q
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OCTOBER 2004
PART I
z From the GCC we can go back and add the utilities to our composite
curves (or shifted composites)

(CC) (GCC)
Tsh ift
H ea t Deficit
Region
H ea t Su r plu s
Region
uop Q Q

(CC) (GCC)
Tsh ift
H ea t Deficit
Region
H ea t Su r plu s
Region
over la p of ??? ???

a n d cold st r ea m
Q Q
Utility Pinch!
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OCTOBER 2004
PART I

What about the cold utility in the region(???) of the composite
curve.
z The utility temperature overlaps with the process temperature.
z Apply the usual temperature overlap treatment. .
(CC) (GCC)
Tsh ift
H ea t Deficit
Region
Ut ilit y
H ea t Su r plu s
P in ch es
Region
P r ocess
P in ch
uop Q Q
What has happened to the targets as we introduced different

utility levels?
z Number of exchangers (changed).
z Number of shells (changed).
z Capital costs (changed).
z Utility costs (changed).
z Total hot and cold utility (remained the same).
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OCTOBER 2004
PART I
Class Exercise - Create Grand Composite Curves for the

Platforming problem with Tmin = 40F
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COMPOSITE CURVES
1000
800
600
40 F
400
200
0
0 50 100 150 200 250
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OCTOBER 2004
PART I
SHIFTED COMPOSITE CURVES
1000
800
600
400
200
0
0 50 100 150 200 250
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GRAND COMPOSITE CURVE
1000
800 800
600 600
400 400
200 200
0 0
0 50 100 150 200 250 0 50 100 150
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OCTOBER 2004
PART I
The grand composite curve is good for visualizing:

z Overall utility requirements.
z Intermediate utility load distribution.
T T
oil
oil
HP
MP
LP GE N
Q Q
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Possibilities can be seen at a glance.

z Pockets represent process-process heat exchange.
z Pockets point to possibilities for recovering heat at a higher
temperature and utilizing heat at a lower temperature.
) e.g., Generate MP steam and use LP steam for heating.
T
HP upper part of pocket - excess heat
MP St ea m
Gen
LP
pin ch
lower part of pocket - needs heat
Q
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OCTOBER 2004
PART I
In the previous example, steam was generated above the pinch!

Is this a good idea?
When?
What about the targets?
uop
The grand composite can also tell you about furnace design
Theoretical
Flame
Temperature FG
(TFT)
Are we getting good
T value from our flue gas,
HP
or could we do better?
MP
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OCTOBER 2004
PART I
The grand composite can also tell you about furnace design
TFT
Strictly, pinch analysis says we
FG
should recover heat from hot
utilities all the way to the pinch
T temperature. This reduces the
HP
amount of HP and MP steam,
MP without increasing FG cost.
Can anyone see a problem with

this?
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GRAND COMPOSITE CURVES: FURNACES
How can we control the

temperature on all three process
passes?
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OCTOBER 2004
PART I
GRAND COMPOSITE CURVE: FURNACES
So what can we do in cases

Tbridgewall =1450F
like the Platformer where
we have a lot of heat left in
the FG?
T 800
600
400
200
0
0 50 100 150
uop Q
GRAND COMPOSITE CURVE: FURNACES
Tbridgewall =1450 F
Use the convective section
to generate steam
T 800
600
HP steam generation 400
200
0
0 50 100 150
uop Q
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OCTOBER 2004
PART I
What have we achieved?

z Estimated minimum requirements of individual hot and cold
utilities
) Important for understanding process operating costs
z Developed targets for high temperature heat input
) Process fuel consumption
) Recovery of waste heat from furnace convective section
z Exploit pockets to reduce utility costs
z Can also be used to design refrigeration systems.
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NETWORK DESIGN
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OCTOBER 2004
PART I
NETWORK DESIGN
Objectives - Place heat exchangers such that:

z The final network is reasonable and practical.
z Utility targets are met.
z T is close to optimal (see composite curves).
Possible Approaches
z Guess - Use the standard approach and check the suitability.
) This can take a long time and never meet the criteria.
z Place heat exchangers per existing P&I modules, check suitability
and fix poor heat exchange matches.
) This can be time consuming.
z Use the pinch design method.
) Start by making matches at the pinch
) Design to make heat transfer as vertical as possible
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NETWORK DESIGN
Consider the network for the grid as shown..
250 C 150 C Tmin = 15 C

H1
200 C 150 C 150 C 60 C
H2
150 C 55C
H3
110 C 45C
C1
160C 135C 135C 75C C2
40 C 30C
C3
pinch
How can heat be removed from both H1 and H2?
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OCTOBER 2004
PART I
NETWORK DESIGN
Whatever Q is, we can no longer match H1 and C2 at the pinch.
H1 250 C MCp = 1 150 C Tmin = 15 C

H2 200 C MCp = 1 150 C 150 C 60 C
150 C 55C
H3
Q=?
110 C 45C
C1
160C MCp = 6 135C 135C 75C C2
40 C 30C
C3
pinch
Why?
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NETWORK DESIGN
Why?
z C2 is leaving the heat exchanger hotter than 135 C.
z H1 needs to get to the pinch at 150 C.
z A C2 and H1 match will always violate Tmin .
Rule #1: Nout Nin at the pinch.
z The number of streams leaving the pinch must be number of
streams entering the pinch.
What can we do?
z Split C2 into 2 streams.
z Exchange C2 against H1 and H2 in parallel.
Examples - FCC/Gas Con (e.g. Yukong)
z Main Column bottoms split into two streams.
z C3 Splitter Reboiler - split duty
uop z Crude preheat train - crude must be split above pinch
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OCTOBER 2004
PART I
NETWORK DESIGN
H1 250 C MCp = 1 150 C

MCp = 1 150 C 150 C
H2 200 C 60 C
150 C 55C
H3
110 C 45C
C1
MCp = 2
160C 135C 135C 75C C2
40 C 30C
MCp = 4 C3
pinch
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NETWORK DESIGN
Consider the following two streams isolated from the grid...
pinch
200C MCp = 2 150C
H2
160C MCp = 1 135C C2
Suppose a duty of x units of heat.

Fix pinch temperatures at 135C and 150 C. (Tmin = 15 C)
Solve for TC2,out and TH2,in [Use Tout = Tin + Q/(MCp)]
z TC2,out = 135 + x/1, TH2,in = 150 + X/2
z T = TH2,in - TC2,out = 150 + X/2 - (135+x) = 15 - x/2
Regardless of x, Tmin is in violation. Why?
uop
45
OCTOBER 2004
PART I
NETWORK DESIGN
Recall from single heat exchanger discussion.
z If [MCp]hot > [MCp]cold, then minimum temperature approach is at
the hot end of the exchanger.
Pinch ?!?
Rule #2: MCp,out MCp, in for each pinch heat exchanger.
uop
NETWORK DESIGN
To Summarize.
N ou t > N in ?
Y N
split ou t st r ea m
MCp ou t > MCp in ?

Y N
split a st r ea m
(u su a lly in )
pla ce H Xs Apply Rules #1 and #2 at the pinch only.

uop
46
OCTOBER 2004
PART I
NETWORK DESIGN
Finally, another Rule to be applied at all times.

Rule #3: Exchange heat as vertically as possible.
uop
NETWORK DESIGN
Exercise: complete the network design for the Platforming

example below the pinch
Strm MCp
400 150
7 0.25
400 150 8 0.15
300 150 5 0.15

360 260 1 0.25
120 90
Air
100 70 CW
uop
47
OCTOBER 2004
PART I
NETWORK DESIGN
Start by matching streams at the pinch

z This completes stream 1
Strm MCp
400 150
7 0.25
400 150 8 0.15
300 150 5 0.15

360 260 9 1 0.25
120 90
Air
100 70 CW
uop
NETWORK DESIGN
Now fill in away from the pinch
Strm MCp
400 150
7 0.25
400 150 8 0.15
300 150
9 5 0.15
360 260 9 1 0.25
120 90
Air
100 70 CW
uop
48
OCTOBER 2004
PART I
NETWORK DESIGN
Now fill in away from the pinch
Strm MCp
400 150
9 7 0.25
400 150 9 8 0.15
300 150
9 5 0.15
360 260 9 1 0.25
120 90
Air
uop
Still to come next time:
PROCESS MODIFICATIONS
z This is where we find most of the benefits
DATA EXTRACTION
z This is where most people get into trouble
PINCH DESIGN TOOLS
z Software, resources, etc.
UOP CASE EXAMPLES
uop
49
OCTOBER 2004
PART I
PROCESS
MODIFICATIONS
uop
50

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INTRODUCTION TO PINCH TECHNOLOGY

INTRODUCTION TO PINCH TECHNOLOGY

ENGINEERING TRAINING SESSION

How much does a 106 Btu/h cost?

Utility Unit Cost Annual Energy Cost*

* Assuming 8000 operating hours per year.

Consider a single heat exchanger.

Look at the heating and cooling curves.

If T2 (hot outlet) < t2 (cold outlet)

What about phase change?

Consider a simple system.

Plot Temperature vs. Duty.

What happens as Tmin approaches 0?

How does Tmin affect the system?

Utility Costs Annualized Capital Cost Total Cost

Other factors to consider besides annualized cost.

What about a slightly more complicated problem?

Stream MCp Tsupply Treqd Duty (Q)

H1 0.050 315 240 -3.75

How many heat exchangers?

Propose a solution. Maximum utilities.

Steam 350 350

Steam Load = 23.00 CW Load = 23.75

uop Is this a good design?

Propose another solution.

Steam 350 12.50 350

240 206 140

Steam Load = 12.50 CW Load = 13.25

uop Is this better?

A SYSTEMATIC APPROACH IS NEEDED!

NEED TO MAKE SOME SIMPLIFYING ASSUMPTIONS

HOW ABOUT PINCH TECHNOLOGY?

All this without designing any heat exchangers.

Benefits of Pinch Technology

How does one handle multiple streams that have temperature

Multistage Reactor Example - Description

Streams A and B have overlapping duties between 520 and 550.

Multistage Reactor Example - Stream Data

Range T in T out Streams M*Cp Q

Plot T vs. Q for each temperature range.

Multistage Reactor Example - Composite Curve

Reactors & Reheats Recycle Gas

Class Exercise - Create Composite Curves for a Platformer

Strm Tin Tout T MCp Q

1 260 980 720 0.25 180 cold

What is the minimum possible utility?

How many exchangers are required?

h1 & h2 c2 Below the pinch:

Increase Tmin. How many exchangers are now required?

Above the pinch:

h1 & h2 c2 Below the pinch:

What happens as Tmin is increased?

What is the optimum heat exchange arrangement?

What happens if we start doing heat exchange that is not vertical?

Rule: Transferring heat across the pinch leads to

c1 & c2 Qex hot

What have we achieved?

Contributions - a concession to practicality.

Contribution = Tmin utility - Tmin global/2

Now Tmin global can be large while still allowing a reasonable

GRAND COMPOSITE CURVES

Grand composite curves aid in selection and placement of utilities.

Not all the heat has to be supplied at T1.

GRAND COMPOSITE CURVES