Application of PINCH Analysis Software

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So far, you have been taught on how to determine the energy target and design the heat exchanger
network that will attain it respectively
Temp.
Enthalpy (H)
QC
QH
DTmin
COLD UTILITIES
HOT UTILITIES
PINCH
POINT
Composite Curve Problem Table Algorithm
and Heat Cascade Diagram
alternatives
HOT 1
HOT 2
COLD 1
COLD 2
180 C
80 C
130 C 40 C
30 C 120 C
60 C
100 C
Cp Q
20
40
36
80
2000
3600
3240
3200
800
2400
1080
70 C 43 C
60 C
2000
160
120
90 C
115.56 C
PINCH
Energy Targeting
Maximum Energy Recovery Design
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Now we will learn on how to use a software that can perform the PINCH Analysis ..
The software is called STAR and was developed by University of Manchester
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Let us suppose we do the data extraction for the process below .
R1
S1
S2
CW
FEED
T = 30 C
T = 200 C

T = 350 C
BOILER FEED WATER
MP STEAM
T = 220 C
T = 90 C
MP STEAM
T = 220 C
T = 100 C
T = 250 C
T = 150 C
T = 60 C
T = 130 C
T = 150 C
T = 180 C
T = 120 C
MP STEAM
T = 220 C
T = 150 C
CW
T = 40 C
PROD 1
T = 60 C
PROD 2
T = 40 C
PROD 3
T = 40 C
CW
CW
LP STEAM
T = 120 C
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So where are the streams ?
R1
S1
S2
CW
FEED
T = 30 C
T = 200 C

T = 350 C
BOILER FEED WATER
MP STEAM
T = 220 C
T = 90 C
MP STEAM
T = 220 C
T = 100 C
T = 250 C
T = 150 C
T = 60 C
T = 130 C
T = 150 C
T = 180 C
T = 120 C
MP STEAM
T = 220 C
T = 150 C
CW
T = 40 C
PROD 1
T = 60 C
PROD 2
T = 40 C
PROD 3
T = 40 C
CW
CW
LP STEAM
T = 120 C
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FEED
30 C
200 C
S1 REB
130.1 C 130 C
130 C 150 C
S1 EFF
180.1 C 180 C
S2 REB
350 C
100 C
REACTOR EFF.
S1 COND
60.1 C 60 C
180 C
40 C
PROD 3
S2 COND
120.1 C 120 C
120 C
PROD 2
40 C
UTILITIES : COOLING WATER, MP STEAM AND LP STEAM
These are the set of streams extracted from the process flowsheet.
H (Enthalpy change)
2,500 kW
3,000 kW
1,200 kW
2,000 kW
600 kW
2,500 kW
3,500 kW
150 kW
2,300 kW
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To start with, go to the file option and click new.
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You will be asked to put some description here
Then click finish
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Go to the edit menu .
Click at stream data
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You will be required to fill up all the streams data
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After filling up the stream data click ok
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Go to the target menu .
Set your DT
min
.
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As you change your DT
min
, the energy target for hot and cold utility will also vary
The energy target for the
two utilities.
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You can also go back to the target menu, and select to see the problem table, composite curve, grand composite
curve and design grid .
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Composite Curve
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Problem Table actually heat cascade
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Grand Composite Curve
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Design Grid representing stream data.
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Another software that can be used is called SPRINT and was also developed by the University of
Manchester.
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In order to input the stream data, similar steps as applied in STAR is used.
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You can basically obtain the same information for the MER target - Problem table, Composite
Curve, Grand Composite Curve, Design Grid etc.
You will also need to set the DT
min
.
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Consider the flowsheet for the Phthalic Anhydride Production Process below,
Perform the stream extraction exercise
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Process Description
The phthalic anhydride is manufactured using controlled oxidation of o-xylene. The reaction uses a fixed bed
vanadium pentoxide titanium dioxide catalyst. The reaction is carried out in vapour phase at a temperature
range of 380 400 C. Reaction is exothermic. Reactor cooling is by means of a molten salt loop.

Air and o-xylene are heated and mixed in a venturi where the o-xylene vapourises. The gaseous reactor
product is cooled first by boiler feedwater before entering a cooling water condenser. The phthalic anhydride
forms a solid on the condenser tube walls and is cooled to 70 C. Periodically the condenser is taken off line and
the phthalic anhydride melted off the surface by recirculation of high pressure hot water. Two condensers are
used in parallel. The noncondensible gases contain small quantities of byproducts and traces of phthalic
anhydride are scrubbed prior to venting it to atmosphere.

The crude phthalic anhydride is heated and held at 260 C to allow some byproduct reactions to go to
completion.

Purification is by continuous distillation in two columns. In the first column, maleic anhydride, benzoic and toluic
acids are removed as the overhead. Pure phthalic anhydride is removed as the overhead in the 2
nd
column
while the high boiling residues are removed as the bottoms.
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The hot stream locations
Perform the stream extraction exercise
1
2
3
4
5
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The hot streams on grid diagram .
Reactor Cooling
377 C 375 C
376 C 180 C
180 C 70 C
280 C 279 C
197 C 196 C
Reactor Product Cooling
Product Sublimation
Column 1 Condenser
Column 2 Condenser
DH
-7000
-3600
-2400
-400
-800
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Perform the stream extraction exercise
1
2
6
3
4
5
Next, lets work out the cold stream .
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Air Feed
O-xylene Feed
Product Melting
Holding Tank Feed
Column 1 Reboiler
DH
200
1600
900
200
400
Column 2 Reboiler 700
160 C 60 C
130 C 20 C
180 C 70 C
260 C 160 C
291 C 290 C
236 C
235 C
The cold streams on grid diagram .
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Overall
Reactor Cooling
377 C 375 C
376 C 180 C
180 C 70 C
280 C 279 C
197 C 196 C
Reactor Product Cooling
Product Sublimation
Column 1 Condenser
Column 2 Condenser
DH
-7000
-3600
-2400
-400
-800
Air Feed
O-xylene Feed
Product Melting
Holding Tank Feed
Column 1 Reboiler
200
1600
900
200
400
Column 2 Reboiler 700
160 C 60 C
130 C 20 C
180 C 70 C
260 C 160 C
291 C 290 C
236 C
235 C
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Now attempt the simulation study using the software
Obtain the following from the software;
i. Composite curve
ii. Problem Table (Heat Cascade)
iii. Grand Composite Curve
iv. Grid Diagram

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Stream Data Entry
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i. The Composite Curve
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ii. Problem Table (Heat Cascade)
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iii. Grand Composite Curve
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iv. Grid Diagram