Applying pinch technology to

energy recovery
A pinch technology-based study of heating and cooling of material streams
in a large-scale olefins plant identifies major opportunities for energy savings
FARBOD RIKHTEGAR Iranian Fuel Conservation Company
SEPEHR SADIGHI Research Institute of Petroleum Industry

nergy saving is one of the

most important issues associated with cost, regulations
and environmental performance
in the petroleum and petrochemical industries. Most of the
available methods for energy
targeting,
retrofitting
and
design of heat exchanger
networks are based on the
pinch method.
The term pinch technology
was introduced by Bodo
Linnhoff in 1991 to represent a
thermodynamically based methodology
that
guarantees
minimum energy levels in the
design of heat exchanger
networks (HEN); therefore, this
approach has been used to save
energy in processes and across
complete sites. Wherever heating and cooling of material
streams take place, there is a
potential opportunity to save
energy. The design philosophy
starts at the heart of the onion
model, the reactor, and moves
out to the separation system
(see Figure 1). Heating and
cooling duties for the next layer
of the onion are the heat recovery systems. Consequently,
targets can be set for the HEN
to evaluate the performance of

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can be utilised to determine

scope for reducing energy
consumption and costs. In
particular, the article demonstrates how the technologys
design methodology can be
used for improving the heat
recovery networks of an olefin
plant, as a case study.

Separator
Utilities
Reactor
Heat
exchanger
network

Figure 1 Onion model

the process design, and it can

enable both the energy and
capital costs of the HEN to be
assessed. It is obvious that,
without a screening approach,
selection between many design
options
cannot
be
easily
afforded in terms of the time
and effort required.
In this article, the discussion
covers the basic principles and
capabilities of pinch technology, and how the technology

Pinch technology
Composite curve

For analysing a heat exchanger

network, sources of hot and
cold streams (source and sink)
should be first identified using
material and energy balances.
For instance, the current typical
flow sheet of a chemical
process is shown in Figure 2.
The supply and target temperature and enthalpy changes of
four process streams are also
given in Table 1.
Consider steam at 200C and

Stream data
Stream no
1
2
3
4

Stream type Supply temp, C Target temp, C

Hot
180
80
Hot
130
40
Cold
60
100
Cold
30
120

H, kW CP, kWC
2000
20
3600
40
3200
80
3240
36

Table 1

PTQ Q4 2013 1

60C
Condenser
100C
72C

H 3200
heater

Reboiler
H 3600
cooler

120C

30C

130C

H 3240
heater

40C

180C

Reactor
1

80C

Reactor
2

H 2000
cooler

Figure 2 Flow sheet of a case study

250
Hot composite curve

Temperature, C

Cold composite curve

Heat recovery pinch

180
150
100
Tmin = 10C

50

H
Figure 3 Current case composite curve

250

Hot composite curve

QHmin = 960

Cold composite curve

Temperature, C

200
150

To achieve the lowest DTmin,

the type of heat exchanger and
fluid regime are important. In
Table
2,
the
minimum
approach
temperature
for
several industries is shown. As
a rule of thumb, rating with a
DTmin less than 10C should be
avoided. The correct setting of
composite curves is defined by
an economic trade-off between
energy and capital cost. In
Figure 5, the trade-off between
energy,
capital
cost
and
economic amount of energy
recovery is illustrated; thus, the
trade-off can be carried out
using energy and capital cost
targets.

Utility selection

100
Tmin = 10C

50
QCmin = 120

H
Figure 4 Composite curve of targeting case

2 PTQ Q4 2013

cooling water at 20 for heating

and cooling utilities, respectively. It is preferable to
recover as much heat as possible between process streams.
The scope for heat recovery
can be determined by plotting
all streams on a T-H diagram
(see Figure 3). This figure
shows DTmin=10C for the
proposed flow sheet; therefore,
the hot and cold utility recoveries are 960 and 120 units,
respectively (see Figure 4). It
can be concluded that DTmin
determines the relative location
of the hot and cold streams, so
it is an important variable for
setting the amount of heat
recovery.

After recovering the heat using

process-process heat exchangers, the remaining required
heat for the plant should be
obtained by the utility system.
In pinch analysis, the grand
composite curve (GCC) is an
appropriate tool to show the
interface between the process

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Heat exchanger area target

It is possible to predict the

required surface area for the
whole problem by using vertical enthalpy intervals. The area
calculated with this model is
minimised when the heat
transfer coefficients of all
streams are equal. For each
enthalpy interval, we can
predict the required area from
the composite curves. The duty
and heat transfer coefficients of
the streams are obtained from
the stream data, and the
log-mean temperature difference (DTLM) is derived from
the composite curves (see
Figure 7).

Industrial recommended DTmin

Industrial sector

Oil refineries
Petrochemicals
Chemical plants
Low-temperature processes

Experience
DTmin value
20-40C
10-20C
10-20C
3-5C

(DTmin),
examine
capital/
energy trade-off, and set the
basis for the heat exchanger
networks design. Additionally,
the software can be integrated
with other process simulators,
such as PRO II and Hysys.

Case study
Table 2

is a suite of programs to optimise the energy consumption

and utilities of a plant by
applying
pinch
analysis.
Furthermore, it enables the
user to determine the absolute
maximum potential for heat
recovery, estimate utility and
capital costs for a given heat
recovery, determine the minimum approach temperature

As a case study, an olefin plant

located in the south of Iran at
Bandar Imam was considered.
The capacity of the plant is 411
000 t/y of ethylene product.
Process data was taken from
design process flow diagrams
and from discussions with
operating engineers. Due to the
significant
differences
in
temperatures and economics of
operation, the olefin unit was
separated into cold and the hot

Cost

and the utility system (see

Figure 6).
In this method, our aim is to
use the specified utility at an
appropriate level. Thus, for the
hot utility, we should use the
lowest temperature and generate the highest temperature. In
contrast, for the cold utility, we
should use the highest temperature and generate the lowest
temperature.

Total
Energy
Capital

Capital cost target

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Tmin
B

QHmin

Hot composite curve

Cold composite curve

Temperature

The capital cost of a heat

exchanger network is mainly
dependent on the surface area
of each heat exchanger, the
number of shells, the material
of construction, the heat
exchanger type and the pressure rating. However, the key
in capital cost targeting is the
surface area required for
exchangers that are included in
the network. For the total cost
targeting procedure, lots of
appropriate software has been
introduced, but SuperTarget
from KBC is particularly
regarded for handling energy
targeting projects. SuperTarget

Tmin

QCmin

Figure 5 Balanced composite curve

PTQ Q4 2013 3

Temperature

Temperature interval

QHmin

QCmin

H
Composite curves

H
Shifted composite curves

H
Grand composite
curve

Figure 6 GCC of a case study

Temperature

7
6
5
4
3

Network area:

Amin =

interval

TLM

qstream
h

Figure 7 Area integrity of a heat exchanger network

900

Hot composite
Cold composite

Temperature, C

800
700
600

Naphtha furnace
product

500
400

Ethane furnace
product

300
200
100
0

Dilution steam

Quench oil
Quench water heat recovery

Column reboilers
Liquid feed

100

200

300

400

500

Enthalpy, GJ/h
Figure 8 Composite curves for ethylene hot section

4 PTQ Q4 2013

600

700

sections. A DTmin of 10C was

chosen to identify future potential savings. The stream data
and composite curves of the
process
obtained
using
SuperTarget
software
are
shown in Table 3 and Figure 8,
respectively.
Additionally,
the
energy
targets and the pinch temperatures obtained by pinch analysis
are shown in Table 4. This table
confirms that the total potential
savings for the plant studied
amount to 194.8 GJ/h. The
majority of the savings were
achieved through reducing
steam consumption and also by
increasing high-pressure steam
generation.
The GCC related to the utility system is shown in Figure
9. According to this figure, it is
recommended that mediumpressure steam should be used
to increase high-pressure steam
generation at a higher level to
be more beneficial for the
plant.
Moreover, to obtain a cycle
efficiency of 60.7% for the utility system, there are several
potential routes that are

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Energy targets and gaps

Target,
GJ/h
68.2
19.1
87.3

Now, To save,
GJ/h
GJ/h
133.9
65.7
50.8
31.7
184.7
97.4

Target,
Cooling
GJ/h
C: PS steam (gen) 0
C: Cooling water 114.2
C: HP Steam (gen) 148.7
C: Seawater
151.5
C: C3{20C}
6.46
Total cold
420.9
Total energy
508.2

Now, To save,
GJ/h
GJ/h
62.1
62.1
321 .1 206.9
135.1 -13.6
0
-151.5
0
-6.46
518.3
97.4
703.0 194.8

Interval temperature, C

Heating
H: MP steam
H: PS steam
Total hot

900

Process GCC
Utility GCC

800
700

Naphtha furnace
product

600

Ethane furnace
product

500
400
300

U: HP steam (gen)
U: MP steam

200

U: PS steam

100
0

Pygas rec. cooler

Dilution steam
Liquid feed
Quench water heat recovery
U: cooling water

100

200

300

400

Enthalpy, GJ/h
Table 4
Figure 9 GCC for ethylene hot section

dependent on site economics

and impacts on the steam and
power system. The aim is to
minimise consumption in the
condensing turbine and generate power using a combination
of a gas turbine (associated
with the waste heat boiler to
generate high-pressure steam)
and a back-pressure turbine.
Table 5 shows all projects that
can be implemented according
to the study of the olefin site.
Savings and costs are calculated according to financial
criteria. It should be noted that
only relevant, feasible and
achievable
projects
are
included in this report. This
means that other projects with
payback times longer than five
years are ignored. These
projects typically demand huge
investments, and they also
need gas turbines with heat
recovery steam generators or a
high-pressure (100+barg) steam
level.

Conclusion

The best design for an efficient

heat exchanger network is the
result of a trade-off between
fixed and operating costs. Pinch
technology can help to perform

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Ethylene plant hot section stream data

Splits and mixers Matches (showing specified temperatures)

Stream
HX
dH,
TS, TT,
Utility

UpStrm DownStrm Value Name GJ/h
C
C
Liquid feed
EA119 4.9
37 60

EA120 10.4
60 105
Ethane feed
EA121 3.2
30 60
Ethane furnace product
EA107-11 60.3 832 338 HP steam (qen)

EA111 24.5 338 210
Naphtha furnace product
EA101-10 74.8 841 447 HP stearn (gen)
Quench oil
S1
1
166 166

S1
M1
0.0937 EA128 7.4
166 155

S1
M1
0.9063 EA124 62.1 166 155 PS steam (qenl

M1
1
155 155
Upper quench oil
EA120 10.4 155 108
Process water
EA126 3.2
119 127.1

EA128 7.4 127.1 145
Dilution steam 1

EA125 122.2 145 170.5 MP steam

EA129
2
170.5 182.6 MP steam
Dilution stream 2
EA111 24.5 145 168.5
Oil steam blowdown
EA126 3.2 170.5 130.1

EA127
6.2 130.1 43 Coolinq water
Fuel oil rundown
EA122 0.4 142.6 65
Quench water cooling 3
EA131 45.3
55 43 Cooling water
Quench water reheating
EA122 0.4 55.28 65
Quench water heat recovery
TEE-100
1
80.39 80.39

TEE-100 MIX-100 0.3842
80.39 80.39

TEE-100 MIX-100 0.0438 EA119 4.9 80.39 65.41

TEE-100 MIX-101-2 0.012 EA211 1.8 80.39 60.51

TEE-100 MIX-101-2 0.0172 EA206 2.5 80.39 60.42

TEE-100 MIX-100 0.0647 EA428 7.2 80.39 65.41

TEE-100 MIX-101-2 0.0215 EA121 3.2 80.39 60.41

TEE-100 MIX-100 0.4454 EA424 49.4 80.39 65.42

TEE-100 MIX-100 0.0111 EA426 1.2 80.39 65.39

Table 3

the best process modifications

as long as the trade-off in costs
is followed accurately. In this
article, first the principles of
pinch technology, including
composite curve, heat recovery
pinch, utility selection, pinch

principles, capital cost target

and retrofit of heat exchanger
networks, were introduced.
Then, an olefin plant located in
the south of Iran (BIPC) with a
nominal capacity of 411 000
metric t/y of ethylene product

PTQ Q4 2013 5

Bandar Imam olefins plant energy savings

Energy savings

Fuel
Steam saving
ProjectID Description
Type
saving, GJ/h HP, t/h
MP, t/h LP, t/h
01-01 Cracking furnace improvement
Furnace
86.4
01-02 Increase steam pressure generation in gas cracker TLEs
Furnace
0.6
01-03 Reduce steam pressure generation in liquid cracker TLEs
Furnace
-0.9
1.2
01-08 Quench water interchange - deethaniser feed preheat
Heat integration
3.7
01-09 Quench water tower top cooling
Yield opportunity
0.2
01-10 Recover blowdown to dilution steam vessel
Heat integration
0 .1
01-11 Condensate stripper temperature control
Other
0.1
01-12 Optimise dryer regen
Furnace
0.261
01-13 Hydrogen product purity
Yield opportunity
01-14 Preheat demethaniser lower feed
Heat integration
3.5
01-18 Acetylene heat integration
Heat integration
4
01-19 C2= fractionator analysis
Other
1.4
01-20 Recover cold from LLP ethylene
Utilities & power
01-22 Reduce operation of depentaniser
Yield opportunity
1 .8
01-24 Reboilers using propylene refrigeration
Other
1
01-25 Install O2 analysers
Furnace
12.5
01-26 Install stack temperature measurement
Furnace
16.4
01-27 Steam loss reduction program
Vent reduction
7
01-29 Reinstatement of insulation
Other
1.65
01-30 Increase cooling effectiveness
Utilities & power
0.7
01-31 Compressor sophisticated anti-surge controller
Utilities & power
5.8
01-32 Program of seawater surface condensers backflushing
Utilities & power
0.7
01-33 Implementation of furnace operation improvement
Furnace
13.2
01-35 Furnace severity and decoking
Yield Opportunity
01-37 Switch small condensing turbine to motor
Utilities & power
19
01-41 Replace propylene turbine with electric motor
Utilities & power
103
01-42 Commission secondary TLEs
Furnace
9
01-43 Commission turbo expander
Utilities & power
0.3
01-44 Increase HP steam temperature exit superheater
Furnace
-2.0
0.8
01-47 Use oil steam BD to reboil cond stripper
Heat integration
1
01-48 Use C3= 20C recup to reboil DeMeth
Heat integration
4.9
01-49 Recover L P-HP transfer cold
Heat integration
5.5
ME-10 Energy management organisation
Other
17.9
ME-11 Energy management tools
Other
17.9

Elect power
saving, MW

0.04

-1.7
-18.1

Table 4

was selected as a case study.

The plant was separated into
cold and hot sections to
perform a pinch analysis.
Moreover, a cracking furnace
and
super-heater
were
excluded from the analysis. A
DTmin value of 10C was chosen
to express the future potential
savings. It was confirmed
that the total potential savings
are 194.8 GJ/h, and that
the majority of these savings
could be achieved by reducing
steam
consumption
and
increasing high-pressure steam
generation.
Further reading
1 Polly G T, Heat exchanger design and
process integration, Chem. Eng, 1993.
2 Catier M, Pinch analysis revisited: new
rules for utility targeting, Applied Thermal
Engineering, 27, 2007, 16531656.

6 PTQ Q4 2013

3 Linnhoff B, Flower J R, Synthesis of heat

exchanger network, AICHE, 1978.
4 Yoon S G, Lee J, Park S, Heat integration
analysis for an industrial ethylbenzene
plant using pinch analysis, Applied
Thermal Engineering, 27, 2007, 886893.
5 Ahmad S, Smith R, Targets and design
for minimum number of shells in heat
exchanger network, Trans ICHeme, 1989.
6 Linnhoff B, Ahmad S, Cost optimum
heat exchanger networks, Chem. Eng,
1990.
7 Smith R, Chemical Process Design and
Integration, 2005, McGraw Hill.
8 Matijaseviae L, Otmaeiae H, Energy
recovery by pinch technology, Applied
Thermal Engineering, 22(4), 2002, 477484.
Farbod Rikhtegar is a Senior Process/
Energy Engineer with the Iranian Fuel
Conservation Companys (IFCO) Industry
Sector. He holds a MSc in chemical
engineering.

Email: f.rikhtegar@ifco.ir
Sapehr Sadighi is Project Manager,
Catalysis and Nanotechnology Division
in the Catalytic Reaction Engineering
Department of the Research Institute of
Petroleum Industry (RIPI). He holds a PhD
in chemical engineering.
Email: sadighis @ripi.ir

LINKS
More articles from the following
categories:
Energy Efficiency/Energy
Management
Heat Transfer
Process Modelling & Simulation
Petrochemicals

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