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Lecture-1
PROCESS INTEGRATION
Lecture – 2
PINCH TECHNOLOGY – AN OVERVIEW
Lecture – 3 - 6
BASIC ELEMENTS OF PINCH TECHNOLOGY
Lecture – 7- 8
AREA TARGETING
Lecture – 9 - 11
NUMBER OF UNIT, SHELL AND COST TARGETING
Lecture – 12
PINCH DESIGN METHODS – HEURISTIC RULES
Lecture – 13 - 15
DESIGN OF HEN FOR MAXIMUM ENERGY RECOVERY, LOOP
BREAKING & PATH RELAXATION
Lecturer - 16
DRIVING FORCE PLOT AND REMAINING PROBLEM
ANALYSIS
Lecture-1
PROCESS INTEGRATION
Process integration, a part of Process Intensification, is a fairly new term that emerged in
80’s and has been extensively used in the 90’s to describe certain systems oriented
activities related primarily to process design. It has incorrectly been interpreted as Heat
Integration by a lot of people, probably caused by the fact that Heat Recovery studies
inspired by Pinch Concept initiated the field and is still core elements of Process
Integration. It appears to be a rather dynamic field, with new method and application
areas emerging constantly. The Process Integration is defined as “systematic and general
methods for designing integrated production systems, ranging from individual processes
to total sites, with special emphasis on the efficient use of energy and reducing
environmental effects”.
This definition brings Process Integration very close to Process Synthesis, which is
process systems engineering. Process Integration has evolved from a heat recovery
90’s regarded as a “major strategic design and planning technology”. With this
while new processes often can be designed with reduction in both investment and
operating costs.
1
Definition of Process Integration as per International Energy Agency (IEA)
• Process Integration is the common term used for the application of methodologies
safety and yields. Process Integration also refers to some aspects of operation and
maintenance.
curriculum for process engineers in both Chemical and Mechanical Engineering at most
universities around the world, either as a separate topic or as part of a Process Design or
Synthesis course. Research at UMIST has for 25 years been supported by a large number
of industrial companies through a Consortium that was established in 1984. As part of the
International Energy Agency (IEA) project on Process Integration, more than 50 other
universities around the world involved in research in this field have been identified.
Process Design has evolved through distinct "generations". Originally (first generation),
inventions that were based on experiments in the laboratory by the chemists, were tested
2
The second generation of Process Design was based on the concept of Unit Operations,
The third generation considered integration between these units; for example heat
A strong trend today (fourth generation) is to move away from Unit Operations and focus
on Phenomena. Processes based on the Unit Operations concept tend to have many
process units with significant and complex piping arrangements between the units. By
allowing more than one phenomena (reaction, heat transfer, mass transfer, etc.) to take
place within the same piece of equipment, significant savings have been observed both in
The three major features of Process Integration methods are the use heuristics (insight),
about design and economy, the use of thermodynamics and the use of optimization
techniques. There is significant overlap between the various methods and the trend today
is strongly towards methods using all three features mentioned above. The large number
the use of insight, heuristics and thermodynamics, and it then becomes feasible to address
the remaining problem and its multiple economic trade-offs with optimization techniques.
Despite the merging trend mentioned above, it is still valid to say that Pinch Analysis and
Analysis and Knowledge Based Systems are rule-based approaches with the ability to
handle qualitative (or fuzzy) knowledge. Finally, Optimization techniques can be divided
3
into deterministic (Mathematical Programming) and non-deterministic methods
(stochastic search methods such as Simulated Annealing and Genetic Algorithms). One
Process Integration can be applied in following fields of chemical engineering such as:
5. Emission targeting
6. Mass exchange network (water and wastes water management & recovery of
valuable materials)
qualitative
Heuristic
Knowledge
Rules
Based Systems
automatic Hierarchical interactive
Analysis
Optimization Thermodynamic
Methods Methods
quantitative
4
Techniques Available for Process Integration
2. MILP/MINLP Approach
3. State-Space Approach
The term "Pinch Technology" was introduced by Linnhoff and Vredeveld to represent a
new set of thermodynamically based methods that guarantee minimum energy levels in
design of heat exchanger networks. Over the last two decades it has emerged as an
unconventional development in process design and energy conservation. The term ‘Pinch
Technology’ is often used to represent the application of the tools and algorithms of
3
4
Reactor
Separator
Heat exchange network
Utilities
Site-Wide Utilities
Fig. 2 Onion Diagram
5
Pinch technology provides a systematic methodology for energy saving in processes and
total sites. Fig. 2 illustrates the role of Pinch Technology in the overall process design.
The process design hierarchy can be represented by the “onion diagram” as shown below.
The design of a process starts with the reactors (in the “core” of the onion). Once feeds,
products, recycle concentrations and flow rates are known, the separators (the second
layer of the onion) can be designed. The network (the third layer) can be designed. The
remaining heating and cooling duties are handled by the utility system (the fourth layer).
The process utility system may be a part of a centralized site-wide utility system.
A Pinch Analysis starts with the heat and material balance for the process. Using Pinch
that can have an impact on energy savings (onion layers one and two). After the heat and
material balance is established, targets for energy saving can be set prior to the design of
6
Lecture – 2
PINCH TECHNOLOGY – AN OVERVIEW
Department of Chemical Engineering
One of the most practical tools to emerge in the field of process integration in the past 20
years has been pinch analysis, which may be used to improve the efficient use of energy,
hydrogen and water in industrial processes. Pinch analysis is a recognized and well-
Chemical
Petrochemical
Oil refinery
Over the past 20 years, pinch analysis has evolved and its techniques perfected. It
provides tools that allow us to investigate the energy flows within a process, and to
identify the most economical ways of maximizing heat recovery and of minimizing the
demand for external utilities (e.g., steam and cooling water). The approach may be used
Pinch technology analyses process utilities (particularly energy and water) to find the
optimum way to use them, resulting in financial savings. Pinch Technology does this by
making an inventory of all producers and consumers of these utilities and then
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systematically designing an optimal scheme of utility exchange between them. Energy &
water re-use are at the heart of pinch technology. With the application of pinch
technology, both capital investment and operating cost can be reduced. Emissions can be
Pinch analysis (or pinch technology) is a rigorous, structured approach that may be used
to tackle a wide range of improvements related to process and site utility. This includes
Major reasons for the success of pinch analysis are the simplicity of the concepts behind
the approach, and the impressive results it has been obtained worldwide. It analyzes a
(water pinch), in terms of its quality and quantity, recognizing the fact that the cost of
In general, we are using high-value utilities in our process and rejecting waste at a low
value. For example, if we consider energy, we may be burning expensive natural gas to
provide the process with high temperatures heat, and are rejecting heat at low
Pinch analysis now has an establishment track record in energy saving, water reduction,
and hydrogen system optimization. In all cases, the fundamental principle, behind the
approach is the ability to match individual demand for a commodity with suitable supply.
The suitability of the match depends on the quality required and the quality offered. In
the context of utility management, the commodity may be heat, with its quality measured
8
as temperature. By maximizing the match between supplies and demands, we minimize
Process
QUALITIY
WASTE
QUANTITY
(a)
MINIMISE
Pinch
Process
QUALITY
Pinch
ENERGY: WATER:
HYDROGEN
MINIMISE WASTE
9
Carrying out a process engineering project without the input of a pinch study will
analysis tools. They can communicate effectively with clients and undertake
conceptual designs. This explains why we are uniquely qualified to help you get
Pinch technology reveals all the possible savings and their corresponding Financial
benefits.
• It does not bench-mark but takes into account all specific mill factors, age,
processes and the surrounding utility systems with the help of the First and Second Laws
of Thermodynamics. The First Law of Thermodynamics provides the energy equation for
calculating the enthalpy changes (dH) in the streams passing through a heat exchanger.
The Second Law determines the direction of heat flow. That is, heat energy may only
flow in the direction of hot to cold. This prohibits ‘temperature crossovers’ of the hot and
10
cold stream profiles through the exchanger unit. In a heat exchanger unit neither a hot
stream can be cooled below cold stream supply temperature nor a cold stream can be
heated to a temperature more than the supply temperature of hot stream. In practice the
hot stream can only be cooled to a temperature defined by the ‘temperature approach’ of
the heat exchanger. The temperature approach is the minimum allowable temperature
difference Tmin) in the stream temperature profiles, for the heat exchanger unit. The
temperature level at which Tmin is observed in the process is referred to as "pinch point"
or "pinch condition". The pinch defines the minimum driving force allowed in the
exchanger unit.
Pinch applies to a wide range of processes. Pinch originated in the petrochemical sector
applications experience, benefits can now be realized in many other process industries.
Wherever heating and cooling of process materials takes places there is a potential
opportunity. A realistic approach addresses the practical problems specific to each and
• Meaningful targets
• Feasible projects
• Real savings
11
Pinch gives the practical target to aim for that is less than this theoretical
maximum.
Both of the above are done before any detailed design. This target then set the
basis for the design. Most importantly, it gives clear rules about how to construct
a design to achieve the targets. It will also show where the inefficiency lie in the
existing design.
Pinch takes a system-wide view of the problem. This allows one to see interaction
that would be difficult to spot on a process flow diagram or a flow sheet of site
utility system.
Pinch can work with incomplete data. One can refine the data in the areas where
information about geometry, flow sheet structure, etc. Pinch technology is one of
This is related to the design of HEN for a new plant, which is in design stage.
The ideal time to apply pinch analysis is during the planning of process
modifications that will require major investments, and before the finalization of
12
investments can be obtained in a new plant design, since many plant layout and
some capital expenditure. In this case, pinch analysis can be specifically aimed at
strategy for the available opportunities will ensure that site development is
Typical Savings
• BASF AG (Ludwigshafen, Germany), for example, has completed more than 150
retrofit using pinch technology, achieving over 25 % in energy savings site wide.
• In natural gas sweetening, for example, The Ralph M. Parsons Co. (Pasadena,
Calif.) says that pinch technology led to a 10% drop in capital costs and energy
• GE plastics was faced with a requirement of invest $15 million in doubling the
wastewater flow by 50 %.
13
a) Energy reduced by 15-35 % through revamping of HENs based on
pumps.
d) Improved flexibility giving the lowest cost design for different operating
cases.
The potential energy and water consumption savings in major industries sectors
14
Fig. 3 Potential water consumption savings
15
Lecture – 3 - 6
BASIC ELEMENTS OF PINCH TECHNOLOGY – PART I, II & III
Department of Chemical Engineering
There are four key steps of pinch analysis in the design of heat recovery systems for both
1) Data Extraction, which involves collecting data for the process and the utility
system.
Data Extraction
The most time consuming and often most critical step is the identification of the need for
heating, cooling, boiling and condensation in the process. This task is more art than
science, and if not carried out properly, the final design will not be the best possible. It is
quite easy to accept too many feature of the proposed flow sheet, which inevitably results
in the situation where many good opportunities are excluded from the analysis.
In practice, there are a number of situations where heat integration is not desirable.
Examples include long distances (costly piping), safety (heat exchange between
hydrocarbon streams and oxygen rich streams), product purity (potential leakage in heat
16
reasonable strategy is, however, to start by including all process streams and keep the
degrees of freedom open. Later, practical considerations can be used to exclude some of
these streams and degrees of freedom, and the engineer will then at any time be able to
establish the consequences with respect to energy consumption and total annual cost. A
central part of data extraction is the identification of heating and cooling requirements in
the process. The necessary data for each process stream are the following:
Additionally, the following information must be collected on utilities and existing heat
Heat transfer coefficient for cold and hot sides of heat exchangers (kW / m2 C).
Utilities available in the process (water temperature, steam pressure levels, etc),
Data extraction must be preformed carefully as the results strongly depend on this step. A
key objective of data extraction is to recognize which parts of the flowsheet are subject to
change during the analysis (e.g. possibility of making modifications to the piping, or
adding new heat exchangers, possibility of making temperature changes in the process or
modifying the utility that heats a given piece of equipment (MP steam instead of HP
17
steam for example), etc). If, during extraction, all features of the flowsheet are considered
At the beginning of a project it is recommended that all process stream be included in the
operability, control and safety concerns can be incorporated later on. By proceeding in
such a fashion, it is possible to have an objective evaluation of the costs of imposing such
constraints. PI specialists generally include some constraints form the beginning of the
data extraction procedure. This can speed up the overall analysis, but a lot of experience
is required to ensure that potentially interesting heat-recovery projects are not excluded.
There are a lot of sector specifics for data extraction. However, heuristic rules have been
Do not mix streams at different temperatures. Direct non-isothermal mixing acts as a heat
exchanger. Such mixing may involve cross-pinch heat transfer, and should not become a
fixed feature of the design. For example, if the pinch is located at 70C, mixing a stream
at 90C with a stream at 50C creates a cross pinch, and will increase the energy targets.
The way to extract these streams is to consider them independently, i.e., one stream with
a supply temperature of 50C and the required target temperature, and the other stream
Do not include utility streams (stream, flu gas, cooling water, refrigerant, cooling air,
etc.) in the process data unless they are involved directly in the process or they cannot be
replaced. One of the goals of using pinch analysis is to reduce the usage of utilities.
Therefore, if utility streams are extracted in a similar way to process streams, they will be
18
identified. In some cases, utility streams can be included because it is not practical to
replace them by any form of heat recovery. For example, this is often the case for stream
Do not consider the existing plant layout. When selecting the inlet and outlet parameters
for a process stream, existing heat exchange equipment and plant topology should not be
taken into account at first. True utility targets (for cooling and heating) should be set
regardless of the existing plant layout. Current plant energy consumption can then be
compared with minimum energy targets. In retrofit of existing facilities, once these
targets have been determined, plant layout (existing heat exchangers and piping,
distances, etc) needs to be taken into account in order to identify practical and cost-
Identify hard and soft constraints on temperature levels. For example, a hard constraint
would be the inlet temperature of a reactor that cannot be changed in any way, while a
soft constraint would be the discharged temperature of a product going to storage, for
Data extraction is a complex issue, and a significant part of the pinch specialist’s
expertise is related to building a good pinch model during the data extraction phase.
Targeting
before the design step is started. For heat recovery systems with a specified value for the
Minimum Energy Consumption (external heating and cooling), Fewest Number of Units
(process/process heat exchangers, heaters and coolers) and Minimum Total Heat Transfer
19
Area. In addition, the corresponding calculations will also identify the Heat Recovery
Designing
Design of Heat Exchanger Networks in various industries is primarily carried out using
the now classical Pinch Design Method (Linnhoff and Hindmarsh, 1983). While the
original method focused on minimum energy consumption and the fewest number of
units, later graphical and numerical additions made it possible also to consider heat
The basic Pinch Design Method respects the decomposition at Process and Utility Pinch
points and provides a strategy and matching rules that enable the engineer to obtain an
The Pinch Design Method also indicates situations where stream splitting is required to
reach the minimum energy target. Stream splitting is also important in area
The design strategy mentioned above is simply to start design at the Pinch, where driving
forces are limited and the critical matches for maximum heat recovery must be selected.
Optimization
Heat exchange network for maximum energy recovery established by pinch design
method, should only be regarded as initial designs and some final optimization is
required. The matches in the initial network depend on pinch location and since the pinch
point depends on the value of Tmin, this becomes a key parameter in the pinch design
method. By repeating all calculations, for synthesis of HEN, for different values of Tmin,
20
it is possible to identify a good starting value for the level of heat recovery. This exercise
minimum total annual cost is obtained to be 240.42103 $/yr (Fig. 1). Thus, the optimum
ΔTmin is 13 °C.
400
350
300
TAC (1000 $/yr)
250
200
150
100
50
Δ Tmin Optimum = 13 °
0
0 20 40 60
Minimum temperature difference
The
Fig. Total
1 The Annual
total annualCost
cost Profile
profile
Grid Representation
The grid is used to represent heat exchange network more conveniently. The important
Hot streams (streams which require cooling) are drawn at the top running let to
right.
Cold streams (streams which require heating) are drawn at the bottom running
right to left.
21
A heat exchanger is represented by a vertical line joining two open circles on the
streams being matched. The heat exchanger load can conveniently be written
Heaters (H) and coolers (C) can be represented in an open circle on the stream
Temperatures can be put on the grid as shown to allow an easy check on the
The stream data for the typical process is shown in Table 1. The grid representation for
this process, which includes two hot, H1 & H2, and two cold, C3 & C4, streams, are
shown in Fig.2.
22
Composite Curve
The Composite Curves (CCs) are constructed from ‘stream data’ representing a process
heat and material balance. The CCs allow the designer to predict-optimized-hot and cold
utility targets ahead of design, to understand driving forces for heat transfer, and to locate
the heat recovery ‘Pinch’. CCs consist of temperature-enthalpy (T-H) profiles of heat
availability in the process (the “hot composite curves”) and heat demands in the process
(the “cold composite curves”) together in a graphical representation. CCs also provide the
The construction of the hot composite curves (as shown in Fig.3) simply involves the
addition of the enthalpy changes of the streams in the respective temperature intervals.
The CCs for the stream data, given in Table 1, are shown in Fig.3. The QHmin and QCmin
QHmin
200 Region of heat recovery by
process to process exchange
150
T (oC) Tmin
100
Below Above
50 QCmin pinch pinch HCC
CCC
0
0 1000 2000 3000 4000 5000
Heat Content Q (kW)
Fig. 3 The hot composite curves (HCC) and cold composite curves (CCC) respectively
show the heat availability and heat requirement for the overall process.
23
Problem Table Algorithm
The procedure is known as the problem table and is broken down into three stages.
1. Set up shifted temperature intervals from the stream supply and target
temperatures by subtracting ΔTmin /2 from the hot streams and adding ΔTmin /2 to
It is important to note that shifting the curves vertically does not alter the
horizontal overlap between the curves. It therefore does not alter the amount by
which the cold composite curve extends beyond the start of hot composite curve
at the hot end of problem. Also, it does not alter the amount by which hot
composite curve extends beyond the start of cold composite curve at the cold end.
(1)
Where ΔHi = heat balance for shifted temperature interval i and ΔHi is the
If the cold streams dominate the hot streams in a temperature interval, then the
interval has a net deficit of heat, and ΔH is positive. If hot streams dominate cold
24
3. Now, cascade any surplus heat down the temperature scale from interval to
interval. This is possible because any excess heat available from the hot streams
in an interval is hot enough to supply a deficit in the cold streams in the next
interval down. First, assume no heat is supplied to the first interval from hot
cascade feasible, sufficient heat must be added from hot utility to make the heat
flows to be at least zero. The smallest amount of heat needed from hot utility is
Example
The problem table algorithm is explained using the stream data of a typical process given
in Table 2. The minimum approach temperature is 10 °C. The shifted temperatures for
25
Table 3 Stream Data with Shifted Temperature
The shifted temperatures are arranged in decreasing order. The stream population is
shown in Fig. 4 with a vertical temperature scale. The interval temperatures shown in Fig.
4 are set to ΔTmin /2 below hot stream temperatures and ΔTmin /2 above cold stream
temperatures.
26
Then a heat balance is carried out within each shifted temperature interval according to
Eq. 1. The result is given in Fig. 5, in which some of the shifted intervals are seen to have
Now, cascade any surplus heat down the temperature scale from interval to interval
assuming no heat is supplied to the first interval from hot utility (Fig. 6). The first interval
has a surplus of 1.5 MW, which is cascaded to the next interval. This second interval has
a deficit of 6 MW, which leaves the heat cascaded from this interval to be -4.5 MW and
so on. Some of the heat flows are negative, which is infeasible. To make the cascade
feasible, largest negative heat flow from Fig. 6 that is 7.5 MW is added from hot utility to
make the heat flows to be at least zero. The revised cascade is shown in Fig. 7 which
gives one heat flow of just zero at an interval temperature of 145 °C.
27
More than 7.5 MW could be added from hot utility to the first interval, but the objective
is to find minimum hot and cold utility. Thus, from Fig. 7 minimum hot and cold utilities
are 7.5 MW and 10 MW, respectively. The point where the heat flow goes to zero at
shifted temperature 145°C corresponds to the pinch. Thus, the actual hot and cold stream
The composite curves are useful in providing conceptual understanding of the process but
Fig. 6 Cascaded surplus heat from high to Fig. 7 Add heat from hot utility to make
low temperature all heat flows zero or positive
28
Grand Composite Curve
The grand composite curve (GCC) is a graphical representation of the heat cascade. GCC
is based on the same process stream data as Composite Curves. GCCs highlight the
process/utility interface. It gives clear visualization of hot and cold utility and provides an
easy approach to use multiple utilities in the process. For the stream data, shown in Table
Hot utility
Above Pinch
High temperature process
sink profile Pinch
Low temperature process
source profile
Process to process
heat exchange
The overlap between the hot and cold composite curves represents the maximum amount
of heat recovery possible within the process. The source/sink characteristics of process
Targets: Once the composite curves are known, we know exactly how much external
29
The pinch: The process needs external heating above the pinch and external cooling
below the pinch. This tells us where to place furnaces, steam heaters, coolers etc.
More in, more out: An inefficient process requires more than the minimum external
heating and therefore more than the minimum external cooling. For every units of excess
external heat in a process one has to provide heat transfer equipment twice. This insight
Freedom of choice: The “heat sink” and the “heat source” in Fig. 8 are separate. This
designer violates this constraint, he can evaluate the pinch heat flow and therefore predict
Trade-offs: A simple relationship exists between the number of streams (process streams
plus utilities) in a problem and the minimum number of heat exchange units (i.e. heaters,
Thus if designer goes for best energy recovery, designing the “heat source” and “heat
sink” section separately, he or she will incur the need for more units than if the pinch
division had been ignored. Hence a new type of trade-off has been identified, between
energy recovery and number of units. This insight adds to the traditional concept of a
30
Lecture – 7- 8
AREA TARGETING
Department of Chemical Engineering
Area is important in determining heat exchanger network capital cost. Before explaining
the complete procedure to computation of area it is necessary to discuss the principles for
Start by considering the example in Fig. 1a, where two hot streams exchange heat against
a single cold stream. If we assume the overall heat transfer coefficient U is constant for
all exchangers and these exchangers are countercurrent units then the network has an area
of 88 m2.
Fig. 1b shows a different network with stream splitting. Its area is 84 m2. The reason is
that it has better countercurrent behavior in terms of the overall network. In Fig. 1a the
matches are in temperature sequence whereas in Fig. 1b the matches share more of the
available temperature differences by splitting the cold stream. Fig. 1c shows that we can
do better still. The network area is now 77 m2. This is the minimum area for the stream
set as defined. The network has been developed by stream-splitting only where streams
The composite curve of the data for example, shown through Fig. 1, is drawn in Fig. 2.
Overall countercurrent heat exchange now appears as vertical heat transfer on the
composite curves. Partitioning of the stream data to follow the temperatures of the
vertical model then leads to the minimum area design for this example.
31
Fig. 1 (a) network with exchangers in temperature sequence on cold stream; (b) network
with exchangers sharing temperature span of cold stream; and (c) network with
exchangers showing correct distribution of temperatures for minimum area.
32
Fig. 2 Resolving temperature contention using the composite curves: (a) overall
countercurrent heat exchange appears as vertical heat transfer on the composites; (b) the
temperatures of enthalpy intervals show where stream-splitting will be required, (c) these
temperatures can be marked on the grid; and (d) used to guide design for temperature
contention.
To calculate the heat exchanger network area from composite curve, utility streams must
be included with the process streams in the composite curves to obtain the balanced
composite curves (BCC). The resulting BCC (Fig. 3a) should have no residual demand
for utilities. The BCC are divided into vertical “enthalpy intervals”. The intervals are
defined whenever a change in slope occurs in either balanced composite profile. Next, a
network design is considered within each enthalpy interval, which can satisfy vertical
33
heat transfer. Fig. 3b demonstrates this for an interval, which contains two hot streams
and three cold streams. Each hot stream is split into the same number of branches as the
number of cold streams in that interval. Similarly, each cold stream is split into the same
number of branches as the number of hot streams in that interval. Hence, each hot stream
can be matched with each cold stream such that every match occurs between the corner
temperatures of the enthalpy interval. The heat exchanger of these matches must
Fig. 3. Example of general stream splitting and matching scheme for vertical heat
transfer in an enthalpy interval of the balanced composite curves.
The minimum total area could be taken as the sum of the areas of all such exchangers
from all enthalpy intervals. However, this is not necessary if U = constant. From the
composite curves, the area from vertical heat transfer in interval i is simply:
(1)
34
where ΔHi is the enthalpy width of interval i and ΔTLM,i is the logarithmic mean
(2)
This shows that in order to derive an area target based on U = constant no design is
required.
Consider again the design in Fig. 3 for vertical heat transfer in enthalpy interval i of the
composite curves. If the heat transfer coefficients differ then the total area of these
exchangers is:
(3)
Where, Q13 is the duty of the match between streams 1 and 3, U13 its overall heat transfer
coefficient, etc.
Now,
(4)
where h1 is the heat transfer coefficient of stream 1 (including film, wall and fouling
resistances), etc.
35
So,
(5)
But
(6)
so,
(7)
The argument applies in general for other enthalpy intervals. Summing up over all
(8)
This simple formula incorporates stream individual heat transfer coefficients and allows a
“target” for the minimum heat exchange area to be calculated from the composite curves.
Further, within ith enthalpy interval, all hot streams undergo the same temperature change
36
(9)
Example:
Stream Data of a typical process with Tmin = 20˚ C is given in following table.
Minimum hot and cold utilities are calculated by Problem Table Algorithm which are as
follows:
The MCp values of hot utility (hu) and cold utility (cu) are given as:
37
Plotting the Balanced Composite Curves
The procedure for plotting the Balanced Hot Composite Curve and Balanced Cold
Composite Curve is the same as the Hot Composite Curve and Cold Composite Curve,
For BHCC the temperatures of hot streams and hot utility are arranged in ascending order
(Fig. 4). The sum of the MCP values of hot streams and utility present in each interval is
calculated. Then this sum is multiplied by the temperature difference of each interval.
Similarly Balanced cold composite curve can be drawn. The two curves are
superimposed on each other to get BCC as shown in Fig. 6. The BCC are divided into
vertical “enthalpy intervals”. The intervals are defined whenever a change in slope
occurs in either balanced hot composite curve (BHCC) and balanced cold composite
38
curve (BCCC) profiles. The BCC on being divided into enthalpy intervals, allow
200
180
160
Temperature, Deg C
140
120
100
80
60
40
20
0
0 1000 2000 3000 4000 5000
Heat content Q, kW
200
180
160
140
Th,i.
120
BHCC
T (C)
100
Tc,i.
80
Interval i
Th,i.-1
60 BCCC
40 Tc,i.-1
20
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Heat Content Q (kW)
39
Determination of enthalpies for intervals
CumQhb and CumQcb (for BCCC) are merged by omitting cumulative enthalpies common
to both values and the entries are then sorted in ascending order. This identifies all points
Where, Thb,row r and CumQhb,row r are temperature and CumQ in the row r (in which the
18.81
66.25
73.5
79.5
105
149.5
124.5
124.5
40
These are calculated in a manner similar to MCp,hb of Fig. 4. For example, consider first
interval of Fig. 7 where only stream H1 exists, therefore (MCp/h)h = 10/0.2 = 50. Next
four interval contain streams, H1 and H2, thus, (MCp/h)h = 50/0.2 = 50. These data are
shown in Table 1.
Calculation of (Q/h)
This is calculated by dividing the (Q/h) by the corresponding TLM in for the interval.
41
Table 1 Calculation of countercurrent exchanger area
int Thi Tci (MCp/h)h (MCp/h)c (Q/h) TLM, i Ai
0 45 15 0 0 0 0 0
1 65 18.81 50 262.5 2000 37.51 53.31
2 66.25 20 250 262.5 625 46.22 13.52
3 73.5 25 250 362.5 3625 47.37 76.53
4 79.5 40 250 100 3000 43.85 68.42
5 125 105 250 175 22750 28.65 794
6 149.5 112 50 175 2450 27.84 88.01
7 175 124.75 50 100 2550 43.56 58.53
8 179 124.75 0 100 0 52.22 0
9 180 155 3025 100 6050 37.76 160.23
42
Lecture – 9 - 11
NUMBER OF UNIT, SHELL AND COST TARGETING
The capital cost of chemical processes tends to be dominated by the number of items on
the flowsheet. This is certainly true of heat exchanger networks and there is a strong
incentive to reduce the number of matches between hot and cold streams.
Fig. 1 is considered which shows the heat loads on one hot stream and three cold streams
written within the circles representing the streams. The predicted hot utility load is shown
similarly. In this process only hot utility is required but no cold utility. The total system is
in enthalpy balance i.e. the total hot plus utility is equal to the total cold.
Steam Hot
1068 2570
1068
1165 413 992
Matching Steam with Cold1 and maximizing the load completely satisfies or “tick off”
Steam, leaving 1165 units of heating required by Cold1. Matching Cold1 with Hot and
43
maximizing the load on this match so that it “ticks off” the 1165 residual requirement on
So following the principle of maximizing loads, i.e. “ticking off” stream or utility loads
or residuals, leads to a design with a total of four matches. This is in fact the minimum
Thus, Umin = N – 1
Another problem, Fig. 2(a) having two hot streams and two cold streams. Both hot and
cold utility are required. For this problem 5 (N-1) [Where, N = 6.0] units are required
which is obtained by putting the matches using ticking off loads or residuals loads to a
design.
Fig. 2(a). Number of unit is one less than the number of streams included utilities
44
Fig. 2(b). Same principle for separate components – “Subset Equality”
Fig. 2(b) shows a design having one unit less than previous design. The subset of streams
H2, C1 and CW is in enthalpy balance. Similarly, ST, H1 and C2 are in enthalpy balance
(which they must be if the total problem is in balance). What this means is that for the
given data set we can design two completely separate networks, with the formula Umin =
N – 1 applying to each individually. The total for the overall system is therefore (3-1)+(3-
The new unit is placed between ST and C2 as shown in Fig. 2(c). The extra units
introduces what is known as a “loop” into a system. At the hot utility ST, the loop can be
45
traced through the connection to C1, from C1 to H1, from H1 to C2, and from C2 back to
ST.
Suppose the new match, which is between ST and C2, is given a load of X units. Then by
enthalpy balance the load on the match between ST and C1 is 30-X, between C1 and H1,
The features discussed above are described by a theorem from graph theory in
mathematics, known as Euler’s general network theorem. This theorem translates into the
Umin = N + L – s
L = number of loops
Normally we want to avoid extra units, and so design for L=0. Also, if there will be no
subset equality in the data set and then minimum number of unit targets is
Umin = N – 1
Since the pinch divides the problem into two thermodynamically independent regions, the
Shell Targeting
The shell and tube heat exchanger (SHE) is most common type of heat transfer
advantages: (1) the configuration gives a large surface area in a small volume, (2) good
46
mechanical layout: a good shape for pressure operation, (3) uses well established design
procedures and fabrication techniques, (4) can be constructed from a wide range of
Many HEN design methods described in literature make the simplifying assumption of
counter current exchanger. It has been seen that an optimal solution of the HEN problem
based on purely counter current heat exchanger only will remain optimal in practice if
each unit can be realized by one exchanger with single shell. However, it rarely occurs in
feasible to target number of shells than the units at the synthesis stage of HEN.
FT Correction Factor
In case of the simplest multipass SHE, the 1-2 type, the liquid in one tube pass flows in
counter flow while in the other pass flows in parallel relative to shell fluid. To account
counter and parallel flows in 1-2 SHE, a correction factor FT is introduced into the basic
heat exchanger design equation, shown through Eq. 1, to take into account the above
phenomena,
Where,
47
The FT factor is represented as the ratio of actual mean temperature difference in a 1-2
SHE to counter flow Tln for the same terminal temperatures. FT is a function of
Heat capacity ratio, R = CPH / CPC = ((TCo – TCi ) ((THi – THo ) (2a)
Based on the value of FT, feasible design of heat exchanger is screened amongst different
alternative designs. For this purpose a rule of thumb i.e. FT > 0.8 is used and each design
It is well known fact that for multipass exchangers heat recovery is limited by Tln
correction factor, FT. If FT<0.8 one should increase the number of shells till FT becomes
greater than 0.8. For a 1-2 SHE, FT falls sharply with increasing temperature cross. The
passes is increased. However, designers often encounter situations where the FT is too
low or the FT slope is too large. If this happens, the designers may be forced to consider
A method to account for design sensitivity, based on the fact that for any value of R there
is a maximum asymptotic value for P, say Pmax, which is given as FT tends to – , and is
evaluated by
48
Pmax 2/(R 1 R 2 1) (3)
satisfy FT≥0.75, while also avoiding regions of steep slope and therefore assuring a more
reliable design.
Situations are often encountered where FT is too low (or within the present context the FT
slope too steep) for a single shell. If this happens the designer may be forced to consider
an arrangement of multiple shells in series. If multiple shells are required then the most
common practice is to adopt a trial and error approach in which the number of shells in
series is progressively increased until a satisfactory value of FT is obtained for each shell.
Using the constant XP approach any need for trial and error can be eliminated since an
explicit expression for the number of shells can be derived. This is done by using the
R≠1
1RP12
1Y where Y ( )N
P (5a)
R Y 1Pr2
R=1
P P12 N (5b)
P12 N P12 1
P1-2 is the effectiveness of each single 1-2 shell (given by XP * Pmax) whereas P applies
overall to the series of shells. Equations (3) and (4) which together relate P1-2 to XP and
R, can then be used to eliminate P1-2 from equation (5) to give the following expressions:
49
R≠1 N = 1n ((1- RP)/(1-P))/ln W (6a)
Where
In terms of R, P and P1-2, the number of shells can be computed using following
equations:
And
XP is chosen to satisfy the minimum allowable FT (for example, for FT ≥ 0.75, XP=0.90 is
used). The application of XP is valid under the same assumptions as those of FT. Eq. 6 or
7 then evaluates explicitly the number of shells required and, at the same time, ensures
that each shell in the design satisfies the required sensitivity criterion given by the
specification for XP .The number of shells predicted by Eq. 6 or 7 is a real (that is,
fractional or non-integer) number and the actual number of shells in practice would
interval i in equation (6) then the maximum shells count for the interval is:
Ni (Si – 1) (7)
50
The real (non-integer) number of shells target is then simply the sum of the real number
where M is the total number of enthalpy, intervals on the balanced composite curves.
Furthermore, actual designs will normally observe the pinch division. Hence, Nshell
should be evaluated and taken as the next largest integer for each side of the pinch. The
Where the symbol [N] represents the next largest integer to the real number N.
Example
The Stream Data, shown through Table 1, is considered for this purpose. Here Tmin =
20˚ C.
H1 Hot 175 45 10
H2 Hot 125 65 40
C3 Cold 20 155 20
C4 Cold 40 112 15
Hot utility inlet and outlet temperature are 180 ° C and 179 ° C.
51
The temperature effectiveness, P, is defined as the ratio of the temperature change in one
R is defined as the ratio of the heat capacity flow rates of the hot streams to the cold
streams.
N = ln [(1-RP)/(1-P)]ln[(1-RP12)/(1-P12)] for R ≠ 1
And
N = [P/(1-P)]/[P12/(1-P12)] for R = 1
For i = 1,
= 0.2841.
52
Table 2 Determination of P and R for non countercurrent flow
0 45 15
1 65 18.81 0.4000 0.1905
2 66.25 20 0.0263 0.9524
3 73.5 25 0.1355 0.6897
4 79.5 40 0.1101 2.5000
5 125 105 0.5353 1.4286
6 149.5 112 0.5506 0.2857
7 175 124.75 0.4048 0.5000
8 179 124.75 0.0000 0.0000
9 180 155 0.0181 30.250
0 45 15
1 65 18.81 0.4000 0.1905 0.8150 0.2841
2 66.25 20 0.0263 0.9524 0.5400 0.0237
3 73.5 25 0.1355 0.6897 0.6197 0.1160
4 79.5 40 0.1101 2.5000 0.2907 0.2152
5 125 105 0.5353 1.4286 0.4314 1.7304
6 149.5 112 0.5506 0.2857 0.7740 0.5081
7 175 124.75 0.4048 0.5000 0.6875 0.3944
8 179 124.75 0.0000 0.0000 0.0000 0.0000
9 180 155 0.0181 30.250 0.0293 0.3630
53
Table 4 Number of Shell for present problem
0.0237
Cost Targeting
The cost of the network basically comprises the operating cost and capital cost.
Operating cost
The operating cost is the function of energy requirements and is given by:
Where Chu & Ccu are the costs of minimum loads of hot and cold utility respectively and
Qhu,min and Q cu,min are the minimum requirements of hot and cold utilities respectively.
54
Capital cost
CC = a + b Ak (11)
The capital cost of a network can then be predicted on the basis of targets for the number
of units for maximum energy recovery (Umin,MER ) and minimum network area (Amin ).
Thus:
Umin MER Umin MER
CCnetwork CC k aU min,MER b A k aU min .MER bAmin . (12)
k k
Most often, the cost law for individual exchangers takes the nonlinear form as:
If nonlinear cost law is used in targeting, we assume the areas of individual units are all
identical:
Amin
Ak (14)
U min,,MER
Amin
CCnetwork U min a b( c (15)
U min,MER
)
Where Af = (1 + r)t /t
Where Af is the annualization factor, r, is the rate of return of capital interest and t is the
55
Lecture – 12
PINCH DESIGN METHODS – HEURISTIC RULES
Department of Chemical Engineering
The pinch design method incorporates two fundamentally important features. First, it
realizes the pinch is the most temperature constrained region. The design is started at the
pinch and developed moving away. Second, it allows the designer to choose between
options.
The identification of essential matches at the pinch, of a available design options and of
the need to split streams, is achieved by applying three feasibility criteria to the stream
data at the pinch. In developing these feasibility criteria reference is made to "pinch
A pinch match
56
Exchanger 2 is not a
pinch match
The first feasibility criterion concerns the stream population at the pinch. The population
of hot and cold streams has to be such that it will allow an arrangement of exchangers
Consider a hot end design as in Fig. 1(a). Utility cooling above the pinch would violate
the minimum utility objective. Therefore, each hot stream has to be cooled to the pinch
temperature by process exchange. This is attempted in Fig. 1(a) by placing pinch matches
between hot stream No. 2 and cold stream No. 4 and hot stream No. 3 and cold stream
No. 5. Notice, however that having made these matches hot stream No. 1 cannot be
matched with either cold stream without violating the Tmin constraint. Utility cooling
57
would now be required above the pinch to cool stream No. 1 to the pinch temperature. In
such circumstances we say the original stream data at the pinch is not compatible with a
When this incompatibility occurs the streams at the pinch need "correcting" by stream
splitting (see Fig. 1(b)). By splitting a cold stream an extra cold "branch" is created,
To summarize, the hot end stream population at the pinch is compatible with a minimum
utility design only if a pinch match can be found for each hot stream. For this to occur
NH NC (1a)
Where NH is the number of hot streams or branches and NC is the number of cold
streams or branches. Stream splitting may be needed to ensure that the inequality is
fulfilled.
Fig. 1. (a) An infeasible hot end design at the pinch. (b) Stream splitting at the pinch
58
The converse arguments apply below the pinch. To avoid utility heating each cold stream
match is required for each cold stream at the pinch and this is possible only if inequality
(1b) holds
NH NC (1b)
Once again stream splitting may be necessary to ensure that the inequality is fulfilled.
Fig. 2, temperature driving force in a pinch match cannot decrease away from the pinch.
For this condition to be fulfilled the following CP inequalities must apply in every pinch
match
Where CPH is the heat capacity flowrate of a hot stream or stream branch and CPC is the
It should be noted that inequalities (2a) and (2b) only apply at the pinch. Away from the
pinch, temperature driving forces may have increased sufficiently to allow matches in
59
Fig. 2 (a) A feasible pinch exchanger above the pinch (b) A feasible pinch exchanger
below the pinch
The CP difference
To understand the third feasibility criterion at the pinch it is convenient to define the "CP
Similar equations can be written for differences in the overall sum of hot stream CPs and
60
Immediately below the pinch
NH NC
Overall CP difference = CPH CPC
1 1
(4b)
61
Lecture – 13 - 15
The pinch represents the most constrained region of a design; after all, Tmin exists
between all hot and cold streams at the pinch. As a result the number of feasible matches
in this region is severely restricted. Quite often there is a crucial or "essential" match. If
this match is not made, this will result in heat transfer across the pinch and thus in
increased hot and cold utility usage. The pinch design method, therefore
* starts the design at the pinch developing it separately into two remaining problems.
This approach is completely different from the normal intuitive approach of starting the
design at the hot side and developing it towards the cold. When a design is started at the
hot side, initial design decisions may later necessitate follow-up decisions which violate
the pinch. On the other hand, when a design is started at the pinch, initial design
decisions are made in the most constrained part of the problem and are less likely to lead
to difficulties later.
Thus, commencing a design at the pinch has the distinct advantage of allowing the
designer to identify essential matches or topology options in the most constrained region
of the design, which are in keeping with minimum utility usage or maximum energy
62
recovery (MER).
The CP table
Fig. 1(a) and 1(b) show a step-by-step procedure for applying the feasibility criteria such
as: number of process streams & branches, CP inequality for individual matches and CP
* identify the need to split streams and generate stream splitting options at the pinch.
The procedure is aided by the use of another new concept, the "CP table". CP tables for
the hot and cold ends of a typical problem are shown in Figs. 2 and 3 respectively. In
these tables hot and cold stream CPs at the pinch are separately listed in numerical order.
The appropriate feasibility criteria are noted at the top of the table and the CPs
representing streams, which have to be involved in process exchange at the pinch, are
boxed for emphasis. A pinch match is represented in the table by pairing the CPs of a hot
and a cold stream. Stream splits are represented by writing the separate branch flowrate
CPs adjacent to the original CP (see Fig. 3(C)). The step by step procedure from Fig. 1 is
63
Fig. 1. (a) Hot end pinch design procedure. (b) Cold end pinch design procedure.
Fig. 2. (a) The CP table for a typical problem hot end. (b) & (c) Feasible pinch matches
identified in the CP table
64
Fig. 3(a) The CP table for a
typical process cold end.
(b) Infeasible pinch
topologies.
(c) Feasible pinch topology
with two stream splits.
(d) Feasible pinch topology
with one stream split
Once a pinch topology has been chosen, the design of both hot and cold ends must be
continued in such a manner as to keep capital costs at a minimum, i.e. the final designs
ought to be steered towards the minimum number of units. This can be achieved by
employing a "tick-off" heuristic to identify the heat loads on the pinch exchangers.
The targeting equation for the minimum number of units is satisfied if every match brings
one stream to its target temperature or exhausts a utility. In this case, the match is said to
"tick-off" the stream or utility, i.e. the stream or utility need no longer be considered part
The pinch exchangers can usually be made to tick-off streams by choosing each
65
exchanger load to equal the smaller heat load of the two streams matched. The CP
inequalities will guarantee the possibility of choosing pinch exchanger loads by ticking-
off streams as long as the stream CP remains constant with varying temperature and as
long as cold and hot stream temperature overlaps do not require an excessive number of
introducing the need for increased utility usage. Temperature driving force, essential
elsewhere, may be used up excessively in pinch exchangers that are extended too far into
the remaining problem. In such cases the designer can choose either to
* reduce the load on the offending pinch match and run the risk of needing more than
* use another pinch topology in which the tick-off heuristic does not cause essential
The pinch design method incorporates five important stages. These are:
2. The design for these separate problems is started at the pinch and developed
moving away from the pinch. At the pinch essential matches, match options and stream
3. When options exist at the pinch, the engineer is free to base his selection to suit
4. The heat loads of exchangers at the pinch are determined using the stream "tick-
66
topology at the pinch can be chosen or the load on the offending match can be reduced.
5. Away from the pinch there is generally a "free choice" of matches. The procedure
does not insist on particular matches but allows the designer to discriminate between
Example
The stream data is shown below. For this problem Tmin = 10 °C and the hot and cold
utility requirements are 7.5 MW and 10 MW. Hot and cold pinch temperatures are 150
and 140 °C, respectively. Number of units required, including heaters and coolers, are 7
(4 above the pinch and 3 below the pinch). The grid representation of this data is shown
in Fig. 4.
67
Design above the pinch
Fig. 5a shows the grid diagram with CP-table for design above the pinch. Cold utility
must not be used above the pinch, which means that hot streams must be cooled to pinch
temperature by heat recovery. Hot utility can be used, if necessary, on the cold streams
above the pinch. Thus, it is essential to match hot streams above the pinch with a cold
partner. In addition, if the hot stream is at pinch conditions, the cold stream it is to be
matched with must also be at pinch conditions, otherwise the Tmin constraint will be
violated. Fig. 5a shows a feasible design arrangement above the pinch that does not use
temperature differences smaller than Tmin. Note again that the CP inequality only
applies when a match is made between two streams that are both at the pinch. Away from
the pinch, temperature differences increase, and it is no longer essential to obey the CP
inequalities.
NHNC NHNC
(a) (b)
Fig. 5 The CP table for the designs above and below the pinch
68
Design below the pinch
Fig. 5b shows the grid diagram with CP-table for the design below the pinch. Hot utility
must not be used below the pinch, which means that cold streams must be heated to pinch
temperature by heat recovery. Cold utility can be used, if necessary, on the hot streams
below the pinch. Thus, it is essential to match cold streams below the pinch with a hot
partner. In addition, if the cold stream is at pinch conditions, the hot stream it is to be
matched with must also be at pinch conditions, otherwise the Tmin constraint will be
violated. Fig. 5b shows a design arrangement below the pinch that does not use
Sizing the units above the pinch using the tick-off heuristic
Once the matches around the pinch have been chosen to satisfy the criteria for minimum
energy, the design should be continued in such a manner as to keep capital costs to a
minimum. One important criterion in the capital cost is the number of units (there are
others, of course, which shall be addressed later). Keeping the number of units to a
minimum can be achieved using the tick-off heuristic. To tick off a stream, individual
units are made as large as possible, that is, the smaller of the two heat duties on the
Fig. 6a shows the matches around the pinch from Fig. 5a with their duties maximized to
tick off streams. It should be emphasized that the tick-off heuristic is only a heuristic and
can occasionally penalize the design. Methods will be developed later, which allow such
The design in Fig. 6a can now be completed by satisfying the heating and cooling duties
away from the pinch. Cooling water must not be used above the pinch. Therefore, if there
69
are hot streams above the pinch for which the pinch matches do not satisfy the duties,
match to satisfy the residual cooling of the hot streams above the pinch. Again, the duty
on the unit is maximized. Finally, above the pinch, the residual heating duty on the cold
streams must be satisfied. Since there are no hot streams left above the pinch, hot utility
Similarly sizing of units below the pinch can be done as shown in Fig. 7.
The final design shown in Fig. 8 amalgamates the hot end design from Fig. 6c and cold
end design from Fig. 7c. The duty on hot utility of 7.5 MW agrees with QHmin and the
duty on cold utility of 10.0 MW agrees with QCmin predicted by the composite curves and
70
Note one further point from Fig. 8 that the number of units is 7 in total (including the
heater and cooler) which is equal to the targeted value. It therefore appears that there was
something in the procedure that naturally steered the design to achieve the target for the
The pinch design method developed earlier followed several rules and guidelines to allow
design for minimum utility (or maximum energy recovery) in the minimum number of
because one or other of the design criteria cannot be satisfied. In such cases stream
71
Stream data
at pinch
No
No Split cold
stream
Split hot
stream
(a) Stream splitting above pinch
Place
match
Stream data at
pinch
No
No
Split hot
stream
Split cold
stream
(b) Stream splitting below pinch
Place
match
Example
The grid representation for a high temperature process is shown in Fig. 10a where
Tmin=20 C. The process requires 9.2 MW of hot utility, 6.4 MW of cold utility and the
pinch is located at 520 C for hot streams and 500 C for cold streams.
72
Fig. 10b shows the CP tables for the above- and below-pinch designs. Following the
algorithms in Fig. 9, a hot stream must be split above the pinch to satisfy the CP
73
Fig. 10 Maximum energy recovery design with stream splitting
Identification of Loops & Paths and Loop Breaking and Path Relaxation
reduction in the number of units. By transferring heat across the pinch and therefore
increasing the utility usage the number of capital items can be reduced. There is a trade-
off between units (capital cost) and the utility usage (energy cost).
In order to explore the scope for a controlled reduction in the number of units it is
important to understand the concepts of heat load loops and heat load paths.
A loop is a set of connections that can be traced through a network (via streams and
units) that starts at one exchanger and returns to the same exchanger.
Whenever a design features more than the target minimum number of units for the whole
problem, ignoring the pinch, it is due to the existence of heat load loops. There will be
one loop for each extra unit. As an example, the minimum utility design for a typical
74
problem has two more units than the definite minimum according to Fig. 11. Hence there
must be two loops in the design. Figs. 12(a) and (b) show these loops.
An important feature of every loop is that heat loads can be shifted around the loop from
one unit to another. The load is subtracted from the next and so on around the loop. This
load shift always maintains the correct stream heat loads but the exchanger duties are
changed and may cause a violation of Tmin. However, driving forces can be "restored"
75
Heat Load Paths
A path is a continuous connection in the grid between a heater, heat exchangers and a
Load shifts along paths follow equivalent rules to load shifts around a loop. Load is
added to a heater, subtracted from an exchanger, added to the next exchanger in the path,
subtracted from the next, and so on along the path until it is finally added to a cooler.
Stream enthalpy balance is maintained but exchanger loads and operating temperatures
are changed. This last feature means that a path can be used to restore driving forces.
We will now illustrate the use of heat load loops and paths to reduce the number of units
76
It is apparent that load shifts around loops can form the basic mechanism for the
reduction in the number of units. When the load shift around a loop leads to a reduction
in the heat load of a unit, which equals the load on that unit, then the unit is removed
Consider Fig. 12(a), which shows a minimum utility design with seven units. A good
choice of exchanger to remove is exchanger No. 4 as it has the smallest load and forms
part of the simplest loop. Fig. 13 shows the topology and temperatures after the load of
match No. 4 has been transferred to exchanger No. 1. The heat loads of all other units in
the design are unchanged as they were not part of the original loop. There is now a small
However, Tmin can be restored using the heat load path shown in Fig. 14. It is apparent
Requiring T2 to equal 82C, the heat load of individual units can now be changed while
the stream heat loads are maintained by using the path through exchanger No. 1. It is a
trivial task to calculate the hot and cold utility increase x required. This load is 4 kW. In
other words, by supplying a further 4 kW of utility heating and cooling and by reducing
the heat load on exchanger No. 1 by 4 kW, the solution is brought back in line with the
Tmin.
77
Fig. 14 Identifying a path
this we mean that the utility penalty incurred in reducing the number of units is
minimized.
Not all units exist in a suitable loop or along a suitable path. Thus, the procedure
78
Lecturer - 16
Fig. 1 shows two networks having the same CP-ratios for the pinch match. However,
network 2A comes to within 16% of the above pinch area target, while network 2B
requires 108% more area than target. Why is there such a large discrepancy? Examining
the Composite Curves, we suspect network 2B makes poor use of driving forces away
from the pinch. To take this further the concept of “Driving Force Plot” is used.
79
The area target is based on the vertical temperature differences along the whole balanced
matches against the vertical driving forces available on the composites. A simple way of
expressing this is firstly to draw the vertical temperature difference T between the
composites as it changes with the temperature of say the cold composite Tcold (Fig. 2).
Equivalently, T=f(Thot) or Thot=f(Tcold) may also be used. The diagram is called the
Next, individual matches are shown in these coordinates (Fig. 3). Matches displaying
vertical heat transfer on the composites fit the Driving force Plot exactly, such as the
match shown in Fig. 3. Matches which are not vertical (or which criss-cross) on the
composites show a blatant misfit (Fig. 4, 5). Matches using excessive temperature
differences have less area than if they had been vertical, but cause other (subsequently
placed) matches to have smaller temperature differences. The net result overall is
80
Fig. 3 The match with “vertical heat transfer”
The Driving Force Plot provides a rapid and easy way to use guideline for designing
networks, which are close to minimum area. However, it is only a guideline and does not
81
Networks 2A and 2B are displayed against their Driving Force Plot in Fig. 6. The pinch
matches placed according to the CP-rules follow well the slope of the Driving Force Plot
near the pinch. Away from the pinch, however, network 2B shows a poorer overall fit to
the plot. Its pinch matches are too large to duty and under-utilize driving forces away
from the pinch. These duties were established using the “tick-off’ heuristic for obtaining
Fig. 6 Networks 2A & 2B compared on the Driving Force Plot. Network 2B shows a
much poorer overall fit to the plot than network 2A.
The plot shows the tick-off heuristic is inappropriate here for achieving low network area.
Violation of the tick-off rule usually means additional units above target, as in network
2A. The significantly improved area performance in this example gives lower overall
capital cost. Designs achieving a good fit to the Driving Force Plot in minimum number
82
of units or within 10% of this (to the nearest integer number of units) are usually within
10% of the area target.
Remaining Problem Analysis
Suppose a design obtains a good fit to the Driving Force Plot but the final network area is
appreciably above target. Such an occurrence is infrequent considering the plot steers
design towards vertical heat transfer and minimum area. Fig. 7, however, demonstrates
the plot may not always be sufficient for minimum area. Networks 3A and 3B appear
remarkably similar in use of driving forces, but 3B has an area 22% in excess of the
Fig. 7 Both networks show very similar fit to the Driving Force Plot but differ appreciably
in area
83
The Driving Force Plot works in temperatures only, neglecting the effect of duty on heat
coordinates, yet have very different duties. Generally, good utilization of driving forces
When a match is placed, the duty needs to be chosen with some quantitative assessment
of the match in the context of the whole network, without having to complete the
network. This can be done by exploiting the powers of targeting using a technique known
Consider the design for minimum energy in a more complex problem. If a problem table
analysis (PTA) is performed on the stream data, QHmin and QCmin can be calculated. When
the network is designed and a match is placed, it would be useful to assess whether there
will be any energy penalty caused by some feature of the match without having to
complete the design. This penalty can be determined by performing a PTA on the
remaining problem.
The PTA is simply repeated on the stream data, leaving out those parts of the hot and
cold stream satisfied by the match. One of the two results would then occur:
1. The algorithm may calculate QHmin and QCmin to be unchanged. In this case, the
designer knows that the match will not penalize the design in terms of increased
utility usage.
2. The algorithm may calculate an increase in QHmin and QCmin. This means that the
match is transferring heat across the pinch or that there is some feature of the
design that will cause cross-pinch heat transfer if the design was completed. If the
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match is not transferring heat across the pinch directly, then the increase in utility
will result from the match being too big as a result of the tick-off heuristic.
The remaining problem analysis (RPA) technique can be applied to any feature of the
RPA can be used to approach the area target, as closely as a practical design permits,
using a minimum (or near minimum) number of units. Suppose a match is placed, then its
area requirement can be calculated. A RPA can be carried out by calculating the area
satisfied by the match. The area of the match is now added to the area target for the
remaining problem. Subtraction of original area target for the whole-stream data gives the
Targets for number of shells, capital cost and total cost also can be set. Thus, RPA can be
The “Remaining Problem Analysis” is explained in Fig. 8. Suppose the minimum total
area possible for a design completed after accepting a match M is Atotal. M. This is the sum
of the match area aM and the area target for the remaining stream data Ar, M. Subtraction
of the original area target for the whole stream data Amin gives the minimum area penalty
incurred.
The analysis can quantify both surplus and deficit use of driving forces. A large T
match incurs area penalty from the small T caused in the remaining problem. A small
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Fig. 8 Remaining Problem Analysis for area
Fig. 9 the Remaining Problem Analysis for match 4 in network 38 shows significant
penalty in area for the network.
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The Remaining Problem Analyses for networks 3A and 3B are shown in Fig. 9. It is now
clear that match 4 in network 3B is not as good as the rest. Surprisingly, it looks similar
on the Driving Force Plot (Fig. 7) to matches 4 and 5 in network 3A, which return much
lower area penalties. The Remaining Problem Analysis improves on the Driving Force
Plot. At present, it is the only known method for quantifying approach to the targets
The Remaining Problem Analysis discussed so far treats each match in isolation of the
others when several matches exist at any stage of design (as in Fig. 9). In other words, the
remaining problem is defined as the full stream data excluding only the hot and cold
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1. Linnhoff, B.; Dunford; H.; and Smit, R.; “Heat Integration of Distillation
Columns into Overall Process”; Chem. Engg. Science; Vol.38; No.8; pp-1175-
1189, (1983).
2. Robin Smith, “Chemical Process Design”, McGraw Hill, 1995.
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& Marsland R H, “User guide on process integration for the efficient use of
energy”, (The Institution of Chemical Engineers, Rugby, U.K.; available in the
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exchangers networks”, Chem. Eng. Res. Des., Vol. 67, Sep 1989, pp 481-494.
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exchanger
networks”, Chem Engg. Sci, Vol. 38, No. 5 1983, pp 745-763.
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