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Cover Story
Report Part 2
Energy Optimization
Using Pinch Analysis FIGURE 1.
Practical considerations T1 The temper-
atures (T) for
(T3-T 4)*(CPA+CPB)
areas of
overlapping
T4 tempera-
(T4-T 5)*(CPA) tures
T5
Richard Beaman and Cliff Reese
SSOE Group Duty
P
inch analysis is a systematic
method to maximize energy
Composite curve COMMON TERMS
recovery from process streams T1 • Hot stream – Any stream that needs
entering and exiting process to be cooled
equipment. Using this method, the T2 • Cold stream – Any stream that needs
minimum thermodynamic require- to be heated
ments for hot and cold utilities can be T3
T4 • Pinch temperature – The minimum
calculated for a process. This is useful
T5 temperature difference (approach)
to determine areas where savings can between the hot streams and the cold
be realized and where savings are not Duty streams
available. It is a method that can be
FIGURE 2. When the individual T-H • Flowing heat capacity) –
used during the design of a process curves are combined, a composite curve
or after startup. During the design (CC) is created
phase, it is useful to set the tempera- • Composite curve – The sum of the
flowing heat capacity of all of the hot
tures of hot and cold utilities and the cold stream. This is called a composite
or cold streams, over the temperature
load requirements of those utilities. curve. A composite curve is developed
range of the streams
After startup, it can be used to take by compiling the temperature ranges,
advantage of changing utility costs, flowrates (dm/dt), and heat capacities • Outlet temperature – The “desired”
or “required” outlet temperature of
or if a proper pinch analysis was not (CP) of the individual streams. This is
the stream
performed initially, it can be used to illustrated in Figures 1 and 2. Com-
find and correct inefficiencies in the posite curves show where the mini-
heat recovery. mum temperature approach, between
Practical considerations to use these the hot and cold streams, is located. cold utilities. For the complex heat-
techniques effectively are illustrated This is known as the pinch point. The exchanger networks, after all of the
in this article. composite curve also shows how much process streams are integrated into
external hot and cold energy the utili- an efficient network, there may be a
Introduction to pinch analysis ties must provide. This method shows few streams that require one or more
In pinch analysis, a temperature- the minimum utility temperature re- utilities in order to achieve the desired
enthalpy diagram (T-H diagram) is quired to achieve the necessary heat outlet temperatures. If you take each
used to plot the hot and cold streams and the maximum utility temperature of these streams separately and plot
from the process and the tempera- to achieve the necessary coldness. the composite curves for that stream
tures where they are available. The The following analysis technique and the section of the streams that
benefit of this method is that multiple can be used for simple heat-exchanger transfer heat to or from it, you will cre-
hot and cold streams can be plotted on networks (single hot or cold streams) ate a simplified network to which the
the T-H diagram and be represented or complex heat-exchanger networks following techniques can be far more
by a single hot stream and a single for the streams that need hot or readily applied. There are a number of
36 CHEMICAL ENGINEERING WWW.CHE.COM NOVEMBER 2011
Process only unshifted composite curve Unoptimized utilites unshifted composite curve
300 300
Hot utility duty Hot utility duty
42 MBtu/h 42 MBtu/h
250 250
200
Temperature, °F
200
Temperature, °F
150 150
FIGURE 3. When the CCs for the hot and cold streams are FIGURE 4. Adding the utilities to the ends of the respective
plotted and aligned so that the desired pinch point is achieved, hot and cold composite curves can sometimes lead to an un-
the utility requirements can be easily determined optimized solution
Process only shifted composite curve Process only grand composite curve
300 300
Hot utility duty =
250 250
42 MBtu/h
200
Temperature, °F
200
Temperature, °F
150 150
100 100
Pinch point
50 50 Cold utility duty =
114 MBtu/h
0 0
0 100 200 300 400 500 600 700 800 900 1,000 0 20 40 60 80 100 120 140 160
Heat duty, MBtu/h Heat duty, MBtu/h
FIGURE 5. Shifting the hot composite curve down by 1/2 of FIGURE 6. Subtracting the hot CC from the cold CC, at each
the pinch temperature and the cold composite curve up by 1/2 temperature, creates a grand composite curve, which can be
of the pinch temperature creates a shifted composite curve used to determine the temperatures required for the utilities
150 150
Utility pinch
100 points 100
Pinch points
50 50 Cold utility
Cold utility at 65°F
at 65°
0 0
0 100 200 300 400 500 600 700 800 900 1,000 0 10 20 30 40 50 60 70 80 90 100 110 120
Heat duty, MBtu/h Heat duty, MBtu/h
FIGURE 7. Adding the utility streams into the shifted compos- FIGURE 8. Replotting the grand composite curve shows the
ite curve shows how the optimum energy solution can create utilities’ impact on the curve
additional pinch points
articles and resources available that ers, in order to exploit the energy inven- Pinch temperature selection
go into detail on creating the heat ex- tory in the process streams before add- A rarely addressed point that needs
changer networks themselves [1–3]. ing energy (hot or cold) via utilities. to be discussed is how the pinch tem-
There are two features of this ex- perature was determined. Where does
Pinch analysis example ample process worth noting. The hot that number come from? In the train-
Figure 3 shows two composite curves stream enters warmer than the desired ing materials I have read, the choice
that depict the hot and cold utility cold stream outlet, and the cold stream of pinch temperature is usually rather
requirements as 42 MBtu/h and 114 enters colder than the desired hot vague. Materials often mention that it
MBtu/h, respectively. It has a 20°F stream outlet. The implication of this is is the best temperature that the heat
pinch temperature. One thing to note is that it is not necessary to have the hot exchanger network can obtain for this
that only the process streams are plot- utility above the desired cold-stream- type of process. In order to help quan-
ted. The reasoning is that we want to outlet temperature and conversely, the tify the pinch temperature, it is use-
make adjustments to the process, by cold utility does not need to be below the ful to take the following relationships
adding or rearranging heat exchang- desired hot-stream-outlet temperature. into account. The basis of the pinch
CHEMICAL ENGINEERING WWW.CHE.COM NOVEMBER 2011 37
Cover Story
Temperature, °F
200 200
175 175
150 Pinch = 10°F 150
125 125
100 100
75 75
Shifted temperature = 85°F
50 50 Actual temperature = 80°F
Cold utility duty =
25 72 MBtu/h 25 Cold utility = 72 MBtu/h
0 0
0 100 100 100 400 500 600 700 800 900 1,000 0 10 20 30 40 50 60 70 80 90 100 110 120 100 140 150 160
Heat duty, MBtu/h Heat duty, MBtu/h
FIGURE 9. Optimizing the pinch temperature can sometimes FIGURE 10. Optimizing the pinch temperature can sometimes
eliminate the need for a utility even change the type of utility required
temperature is the following heat ture can be used, requiring less sur- Where there is no cold line to subtract
transfer equation: face area per Btu than in the case of the hot duty from, use the duty at the
the low overall heat transfer coeffi- end point of the cold curve. Re-plotting
Q = U0 A LMTD (1)
cient. The above overall heat-transfer- the curve in this manner produces a
Where: coefficient relationship must be used plot as shown in Figure 6. As pointed
Q = the duty of the heat exchanger in conjunction with the size of the po- out earlier, the hot stream inlet is hot-
U0 = the overall heat transfer coeffi- tential utility-duty savings. If the po- ter than the required cold-stream out-
cient tential utility savings are small, there let temperature and the cold stream
A = the heat-exchanger heat-transfer typically isn’t enough savings to jus- inlet is colder than the required hot
surface area tify much capital expenditure for heat stream outlet. These traits produce a
LMTD = the log mean temperature exchangers and piping. grand composite curve that doubles
difference Returning to the example, someone back toward the y-axis. This allows
In this equation, minimizing the not familiar with pinch analysis would us to use the graph to easily find the
pinch temperature increases the heat be tempted to add the utilities at the optimum temperature needed for
recovery (Q) from the process. Mini- end of the hot and cold curves in order the utilities. This is accomplished by
mizing the pinch temperature will to match the end point temperatures. drawing a line from the endpoint of
decrease the LMTD, so in order to Their solution might look similar to each branch of the curve back up or
increase the duty (Q) we need to pro- Figure 4. A novice at pinch analysis down to the adjacent leg of the curve
vide additional surface area (A). In would know that the utilities could and then over to the y-axis.
this example, it is assumed that the be added at a lower temperature, but Utility temperatures. This gives
overall heat-transfer coefficient stays might not know how to determine the the “shifted” temperature of the util-
relatively constant, because trying to optimum temperatures. ity required to achieve the desired
increase the overall heat-transfer co- Shifted composite curve. In order to process-outlet temperature. The ac-
efficient usually requires increasing find the optimum solution, you need tual temperature required would be
the fluid velocities, which increases to re-plot the composite curve as a the shifted temperature plus one half
the pressure drop. Often this pressure “shifted composite curve.” This is ac- of the pinch temperature for the hot
drop is not available due to compressor complished by subtracting one half of utility, and minus one half of the pinch
or pump limitations. It is the overall the pinch temperature from the hot temperature for the cold utility. This
heat transfer coefficient that is used composite curve temperatures and shows that the heat source for this ex-
to determine whether to use a small adding one half of the pinch tempera- ample only needs to be ~159°F versus
or large pinch temperature. Therefore, ture to the cold composite curve tem- 275°F. The cold utility should be ~65°F
it is necessary to have a good knowl- peratures. The resulting plot is shown versus 4°F. A utility at 65°F is usually
edge of the process. If the process heat in Figure 5. This plot shows that the much cheaper to obtain than one at
exchangers have small overall heat hot and cold utility requirements have 4°F, which requires a refrigeration
transfer coefficients near the pinch not changed, but at the pinch point, system. If you choose a colder hot util-
point (such as for vapor-vapor heat the curves now touch. This is mainly ity or a warmer cold utility, you would
exchangers), then it will require a lot done to allow the curves to be re- find that the process would pinch
of extra surface area per extra Btu de- plotted in a different form, to create a before enough heat or cold could be
sired, thereby increasing the capital “grand composite curve.” added to obtain the desired tempera-
requirements significantly. Grand composite curve. The grand tures at the stream outlets.
However, if the overall heat transfer composite curve is created by sub- Inserting the utilities into the shifted
coefficients are large near the pinch tracting the hot curve duties from the composite curve yields the curve
point, then a smaller pinch tempera- cold curve duties at each temperature. shown in Figure 7. Shown on the curve
38 CHEMICAL ENGINEERING WWW.CHE.COM NOVEMBER 2011
Potential savings
of tighter pinch
Annual cost, $/yr
FIGURE 11. A graph of total, energy and capital costs for a FIGURE 12. Sometimes when optimizing the pinch tempera-
typical process ture, as utilities are eliminated or the type changed, discontinui-
ties in the cost curves are created that may save costs
Temperature, °F
40 23°F
Cold liquid 30
process Refrigerated 20
stream inlet (–68°F) 10
0
-10
-20
FIGURE 13. A typical “actual” stream cooling-process diagram -30
-40
-50
-60
are the original process-pinch point, Plotting the un- -70
-80
three new process-pinch points, and shifted composite 0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000
two utility-pinch points. The addition curve would show Heat duty, MBtu/h
of the new process-pinch point at the that we are not FIGURE 14. A composite curve for a “typical” threshold-
very cold end of the composite curves creating a real cooling process
is the result of both optimizing the temperature cross
utility temperatures and having the in the heat exchanger. This will be il- curve, and plot the line from the cold
shifted cold-end temperatures being lustrated in a later example. tail of the curve up to the warmer part
equal (the required hot-outlet and the For illustrative purposes, the grand of the curve and over to the shifter
cold-inlet temperatures were only dif- composite curve can be re-plotted with temperature axis, we find that the
ferent by the pinch temperature). The the utilities to show the impact of add- minimum shifted temperature (tem-
other two, new pinch points are created ing the utilities at the minimum tem- perature of the cold utility) has risen
by the procedure used with the grand perature levels. This step does not need from 75°F to 85°F. After adjusting
composite curve, shown in Figure 6. In to be done as part of the pinch analysis. the shifted temperature back to un-
other words, the procedure minimizes shifted temperatures, the cold utility
the utility temperatures by creating Additional optimization step requirement has gone from 65°F to
additional pinch points. In Figure 3, we used a 20°F pinch tem- 80°F, which takes us from a refriger-
Utility pinch temperatures. The perature, which is a fairly easy target to ated cooling source to cooling tower
above procedure assumes that the util- hit. If we were to change the pinch tem- water. This would save the cost of a
ity would use the same pinch tempera- perature and perform a sensitivity anal- refrigeration system at the cost of a
ture as the process pinch temperature. ysis to determine how the utility duties cooling tower for a significant capital
Often this would be the case. However, vary as a function of the pinch tempera- savings. In addition, the cost of operat-
as mentioned earlier, having a good ture, an interesting result would appear. ing a cooling tower is significantly less
working knowledge of the process When the pinch temperature drops to than operating a chiller system.
may allow the utility to use a differ- 10°F, the hot utility duty drops to zero. To illustrate the effect of this shift
ent pinch temperature. For example, if This is shown in Figure 9. from 20°F to 10°F in pinch tempera-
the process pinches at a vapor/vapor In this case, because there is no lon- ture, we would typically see a cost
portion of the process, where the over- ger a hot utility requirement, we do versus pinch temperature relationship
all heat transfer coefficient would be not need to add the hot utility heat similar to Figure 11. This shows that as
relatively small, and you have a util- exchanger nor the associated equip- the pinch temperature decreases and
ity where a high overall heat-transfer ment (steam traps), piping and control the energy costs decrease, the capital
coefficient could be obtained (that is, a systems. This could save a significant cost and total cost increase, usually ris-
steam heater or cooling water utility), amount of capital, which could be used ing sharply as the pinch temperature
then you could use a smaller utility to pay for the additional heat-transfer decreases toward very small values.
pinch temperature. This would shift surface area required for a tighter However, in the case being examined
the utility curve up (for a cold utility) pinch point. In addition, you would no here, there is a discontinuity (or two).
or down (for a hot utility) and when longer be required to pay for the en- When the hot utility disappears, there
plotted on a shifted composite curve, ergy costs for this heat. is a sharp drop in the capital costs
would actually cross the other stream. If we re-plot the grand composite required. And, when the cold utility
CHEMICAL ENGINEERING WWW.CHE.COM NOVEMBER 2011 39
Process only shifted composite curve Process only grand composite curve
100
100
90
90
80
80
Pinch = 70
70 Process
60
60 23°F 50 pinch point = 23°F
50
Temperature, °F
40
Temperature, °F
40
30
30
20
20
10
10 0
0
-10 -10
-20 -20
-30 -30
-40 -40
-50 -50
-60 -60
-70 -70
-80 -80
0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000
FIGURE 15. The shifted composite curve for a “typical” FIGURE 16. The amount of –68°F refrigerant duty that can be
threshold-cooling process shifted to the –28°F refrigerant system with a 23°F pinch tem-
perature is approximately 2,500 Btu/h
Process only 15°F composite curve Grand composite curve, pinch = 15°F
110 100
100 90
90 80
80 70 Ignore changes
Shifted temperature, °F
70 60 in this section
60 50
Temperature, °F
50
40 40
30 30
20 20
10 -25°F refrigerant shifted
10
0 0 by 1/2 of 15°F – ∆ approach
-10 -10
-20 -20
-30 -30
-40 -40 Duty transferable to
-50 -50 -28°F refrigerant
-60 -60
-70 -70
-80 -80
0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000
Heat duty, Btu/h Heat duty, BTU/h
FIGURE 17. The shifted composite curve for a 15°F pinch FIGURE 18. The grand composite curve for the 15°F process
temperature pinch temperature and 8°F utility pinch temperature will save
approximately 4,500 Btu/h of of –68°F refrigerant duty
switches from a refrigerated system stream outlet temperature is –60°F. line). As the graph shows, by following
to cooling water, both the capital cost The composite curve is shown in the –16.5°F shifted temperature line
and the energy costs drop sharply. This Figure 14. It has a 23°F pinch point (–28°F + 1/2 of the shift temperature =
is illustrated in Figure 12. As can be at the warm vapor inlet and requires –16.5°F) to the grand composite curve,
seen, the total savings can potentially ~10,000 MBtu/h refrigerant duty at we see that we can save approximately
be more than enough to pay for the cost –68°F. This is known as a threshold 2,500 MBtu/h of the low-temperature
of additional surface area that would problem because the pinch is at the refrigeration duty by using some high
be required for the tighter 10°F pinch end of the composite curves, instead of temperature refrigeration duty.
temperature. Therefore, it can be very the middle as is typical. However, since we know that the
useful to analyze the system to see if a If we now plot the shifted composite dew point is about 4°F, and we can split
utility can be eliminated or switched to curve (Figure 15) and then re-plot it as the cold stream into two parts at the
a cheaper utility. a grand composite curve (Figure 16), high-temperature refrigerant’s tem-
we see that the curves are quite differ- perature, we can use a different pinch
Real world example ent from the previous examples. The temperature. This is because we know
As is probably obvious, the preceding grand composite curve is different in that below the dew point, we will be
example was contrived to illustrate that the curve does not turn back on condensing liquids out of the gas and
some very useful techniques devel- itself, so we cannot find a utility tem- we will usually have a higher overall
oped as part of pinch analysis. Figure perature that eliminates the refriger- heat transfer coefficient. Therefore, we
13 depicts an actual process in which ant at –68°F. However, there are some can try using a smaller pinch tempera-
pinch analysis can be applied. The things we can do. In this particular ture, say 15°F. In addition, because we
process is a simple condensation of process, there is also a refrigeration can get an even higher heat transfer
a liquid from a non-condensable gas system operating at –28°F (high tem- coefficient in the refrigerant evapora-
stream. The vapor inlet is above the perature). This is useful because the tor, due to the boiling refrigerant, we
dew point until about three quarters –68°F refrigeration system uses 6 hp will use a utility pinch point of 8°F. In
of the way through the feed/product per ton of refrigeration and the –28°F order to do this, we need to make an
interchanger. The condenser is cooled system uses only 4 hp per ton of re- adjustment to the high temperature
by –68°F refrigerant (low tempera- frigeration. So, we can plot the shifted refrigerant shifted temperature. The
ture), and the condensed liquid is used refrigerant temperature on the grand shifted refrigerant line we will use on
in a different cooling application and composite curve and determine how the 15°F grand composite curve will be:
is therefore not available to pre-cool much low-temperature refrigeration –28°F refrigerant temperature + ½
the vapor inlet stream. The desired hot duty we can save (Figure 16, dotted process pinch – difference in pinch tem-
40 CHEMICAL ENGINEERING WWW.CHE.COM NOVEMBER 2011
Shifted composite curve process only Optimized composite curve
120 120
100 100
Shifted temperature, °F Process
80 80 pinches
Temperature, °F
60 Pinch = 60
23°F 40
40
20 20
0 Pinch = 15°F 0
-20 -20
Utility
-30 -30 pinches
-40 -40
-50 -50
0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000
Duty, Btu/h Heat duty, Btu/h
FIGURE 19. The new shifted composite curve for the 15°F FIGURE 20. The new shifted composite curve for the 15°F
process pinch temperature process pinch temperature with the utilities curves added