SEMESTER FINAL EXAM ASSIGNMENTS

OPTIONAL COURSE II : PINCH TECHNOLOGY

Andono Kusuma Jati

NIM. 21030118110001

“Energy Efficiency Analysis Using Pinch Technology:

A Case Study of Orbit Chemicals Industry

DEPARTEMEN TEKNIK KIMIA

FAKULTAS TEKNIK
UNIVERSITAS DIPONEGORO
SEMARANG
2020
 Chapter I

INTRODUCTION

1. Background

The rising cost of fossil fuels and their negative impact to the environment has made it
necessary for manufacturing industry to reduce energy consumption. Energy audits are
commonly used to improve energy efficiency. However, the audits do not usually involve in-
depth analysis of design features for optimum energy use. Pinch technology analysis, which
involves heat exchanger design and retrofits, is increasingly being used to optimize energy
utilization especially in thermo-chemical industries. Various pinch analysis studies have been
conducted in different manufacturing and processing plants. However, there is no published
literature about pinch analysis studies in the sulphonation process. Presented in this paper is
the application of the pinch technology analysis to a sulphonation process at Orbit Chemical
industries- Nairobi. The aim was to design a heat exchanger network retrofit for energy use
reduction in the sulphonation process and to develop an investment appraisal for the design.

The demand for energy in the industrial sector has been increasing, causing a rise in the
cost of energy and cost of production. Alongside the increased cost of production, increased
use of fossil fuels threatens to increase the amount of carbon dioxide in the atmosphere.
Engineers and other stakeholders in the industrial sector have a task to reduce the demand for
energy. Reduced demand will cause reduced cost of production and reduced emission of carbon
dioxide into the atmosphere. Petrochemical industries, cement factories, oil refineries, steel
mills, paper pulp mill industries and other plants that involve thermo-chemical processes are
classified as energy intensive. The industries can use different methods to reduce the demand
for fossil fuel energy. The industries can use the energy efficiently or substitute the fossil fuels
with renewable energy. Energy efficiency methods include the pinch analysis, emergy, exergy
analysis and use of the learning curves

Pinch analysis is a methodology for reducing the energy consumption of a process by

calculating a thermodynamically feasible energy target (or minimum energy consumption) and
achieving it by optimizing the heat recovery system, energy supply method and process
operating conditions. Also known as "process integration", "heat integration", "energy
integration" or "pinch technology". Such pinch analysis results in substantial financial savings.
The main objective of this method is to save costs by maximizing process heat recovery.

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 The concept of "target before design" was introduced by Linnhoff and Hindmarsh, to
design individual processes that take into account pinch rules. Pinch technology has been
successfully used in various industries, including non-chemical: food industry, paper mills, etc.
to increase the energy efficiency of processes and reduce global energy bills. This method is
based on thermodynamic principles and makes it possible to determine the best heat exchanger
network and utility system. The first step in the targeting stage is to calculate the minimum
heating and cooling requirements for the Heat Exchanger Network (HEN). The Heat Exchanger
Network is a way of utilizing the heat available in a process by exchanging hot flow (as a heat
source) and cold flow (as a heat absorber), so that it can save on utility use in the form of steam
and cooling water, and minimize production costs.

A well-designed HEN can significantly contribute to a reduction in energy consumption

and energy costs. This is done by minimizing utility usage and maximizing heat recovery
between existing hot and cold flows. In this paper, we will discuss pinch analysis and the
manufacture of Heat Exchanger Network (HEN) from a journal source entitled “Energy
Efficiency Analysis Using Pinch Technology:A Case Study of Orbit Chemicals Industry by
Fenwicks, M., Robert, K., & Alex, A using the HINT application.
Target Results:
1. Design the Heat exchanger network
2. Estimate total heat recovered and area of heat exchanger
3. Estimate the % of saving hot and cold utility
Benefits:
1. Students are able to identify the hot flow and cold flow contained in the
journal.
2. Students are able to make composite curves and grand composite curves based on
existing case.
3. Students are able to create a Heat Exchanger Network based on heat flow data
and cold streams present in a process.

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 Chapter II
RESULTS AND DISCUSSION
2.1 Data Analysis from the case study
In this system there are 13 streams consisting of 7 hot flows and 6 cold flows. This data
was obtained from a journal entitled Energy Efficiency Analysis Using Pinch Technology:A
Case Study of Orbit Chemicals Industry. by Fenwicks, M., Robert, K., & Alex, A (2014)

Table 2.1 Process Streams Data from Journal

Stream Cp ṁ Cp.m.
Process Ti (oC) Tf (oC) Q (kW)
type ( kJ/kg.oC) (kg/s) (kW/ oC)
1 COLD 26 160 0,73 1,31 0,957 -128,238

2 HOT 203 8 1,013 0,439 0,445 86,775

3 COLD 26 100 4,18 0,521 2,178 -161,172

4 COLD 100 203,9 2,09 0,525 1,089 -113,147

5 HOT 568,3 527,3 0,82 0,983 0,806 33,046

6 HOT 527,3 451,7 0,9 0,764 0,688 52,0128

7 HOT 584,7 451 0,9 0,754 0,679 90,7823

8 HOT 483,7 460 0,9 0,393 0,354 8,3898

9 HOT 456,3 202,8 0,84 0,18 0,151 38,2785

10 HOT 198,6 28,3 0,71 0,15 0,107 18,2221

11 COLD 24 29 4,18 0,12 0,502 -2,51

12 COLD 26 100 4,18 0,417 1,743 -128,982

13 COLD 100 160 2,09 0,872 0,872 -52,32

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 Table 2.2 Temperature C to K for input in Hint program
Process Stream type Ti (K) Tf (K) m.Cp (kW/K)

1 COLD 299,15 433,15 0,957

2 HOT 476,15 281,15 0,445

3 COLD 299,15 373,15 2,178

4 COLD 373,15 477,05 1,089

5 HOT 841,45 800,45 0,806

6 HOT 800,45 724,85 0,688

7 HOT 857,85 724,15 0,679

8 HOT 756,85 733,15 0,354

9 HOT 729,45 475,95 0,151

10 HOT 471,75 301,45 0,107

11 COLD 297,15 302,15 0,502

12 COLD 299,15 373,15 1,743

13 COLD 373,15 433,15 0,872

* 1 kW/oC = 1 kW/K
From Table 4.1, the total heating and cooling requirements were computed. Process 3w and 11w involved
boiling and thus absorbed the latent heat of vaporization. Process 1 involved melting. This involved
absorption of latent heat of fusion. The latent heat was calculated separate from Table 4.1 as shown:
• Latent heat of fusion for process 1
Specific latent heat of fusion of sulphur × Mass Flow Rate of Process 1 = 54kJ/Kg × 1.31Kg/s= -70.74
kW.

• Latent heat of vaporization for process 3w

Specific latent heat of vaporization of water × Process 3w Mass Flow Rate = 2257 kJ/kg × 0. 521 kg/s=
- 1176kW
• Latent heat of vaporization for process 11w

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 Specific latent heat of vaporization of water × Process 11w Mass Flow Rate =2257 kJ/kg × 0. 417 kg/s=
- 941kW
The total latent heat for the three processes was added to the heating load requirements on
Total heating load requirements = 2.771599 MW
Total cooling load requirements= 0.327507 MW
In order to ensure maximum recovery of heat from the cooling processes during design of a
heat exchange network, the temperatures for Ti and Tf were altered by adding or subtracting
0.5 Δ Tmin. The Ti and Tffor the processes that require heating were increased by a value of 0.5
Δ Tmin. The temperature values for the processes that require cooling were reduced by 0.5 Δ
Tmin[4]. Reference [5] recommends that the Δ T min for processes that involves steam and hot
air should be 10 OC. 0.5 Δ Tmin is 5OC. Table 4.2 shows the shifted temperature ranges for all
the processes. From Table 4.1, the data collected from process 1 was Ti = 26 OC and Tf = 160 OC.
The altered temperature for process 1 is Ti = 31 OC and Tf = 165 OC. The same alteration was
applied on the other processes, increasing the temperature of the processes that need heating
by 5OC and reducing the temperature of the streams that need cooling by 5OC.
Table 4.2: Altered temperature intervals for the processes
Process 1 2 3w 3s 4 5 6 7 8 9 10 11w 11s

T i OC 31 198 31 105 563.3 522.3 579.7 478.7 451.3 193.6 29 31 105

T f OC 165 3 105 208.90 522.3 446.7 446.0 455 197.8 23.3 34 105 165

Ti (K) 304,1 471,15 304,15 378,15 836,45 795,45 852,85 751,85 724,45 466,75 302,1 304,15 378,15
5 5
Tf (K) 438,1 276,15 378,15 482,05 795,45 719,85 719,15 728,15 470,95 296,45 307,1 378,15 438,15
5 5

2.2 Composite Curve

All data in table 2.2 is then entered into the HINT application for data processing then
processed. From all these flows, both hot and cold flows then a composite curve is made where
the x-axis represents heat and the y-axis represents temperature. From the data above, the
composite curve is obtained as follows:

Figure 2.1 Composite curve

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 The composite grand curve is the same as a composite curve but in the form of different.
If the hot and cold flow composite curves are represented by two different lines, on the
composite grand curve of hot and cold flow lines depicted by a line as shown below:

Figure 2.2 Grand Composite curve

2.3 Temperature Interval, Pinch Point dan ΔTmin

With the Temperature Interval that has been obtained, with the help of the HINT software
can be solved by using the Problem Table. From the Problem Table in below, it can be seen
that the pinch point is at a temperature of 368.15 K. This is because at a temperature of 368.15
K produces an enthalphy of 0 kW. In addition to pinch points, from the Problem Table can also
be obtained Heating Duty and Cooling Duty of 19.9375 kW and . respectively 1948.74 kW
Tmin used is 10 K.

Heat Duty

6
 Pinch

Cooling Duty

Figure 2.3 Table Problem/cascade

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 Figure 2.4 Heating Duty and Cooling Duty

2.4 Possible Match

The pinch point value obtained from the table program is at a temperature of 368.15 K, so
that with Based on the pinch point, the top and bottom areas of the pinch can be known. From
these data flow matching, adding utilities and heat exchangers (heat exchanger) so that the
system can run better and save energy. Figure 2.5 below is a schematic drawing of the Heat
Exchanger Networks that can be made based on existing data.

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 Figure 2.5 Heat Exchanger Network

According to Hint, the minimum required heat exchanger is 21 HE. A total of 28 HE was
used to utilize all the existing heat. Of the total The 21 heat exchangers each have their own
specifications. Specifications of each tool can be seen as follows:

Heat Hot Cold Area

H.E. T1 (K) T2 (K) T1 (K) T2 (K) Cost ($)
(kW) Str. Str. (m2)
1 100.152 10 466.75 373.15 2 363.15 3.677.462 0.25797 4956
2 621.087 10 373.15 3.151.045 16 304.15 363.15 0.59321 5238
3 102. 13 373.15 373.15 12 304.15 362.669 32.849 6715
4 2.51 13 373.15 373.15 11 302.15 307.15 3,67E+02 4691
5 70.74 1 373.15 373.15 2 304.15 336.144 13.855 5756
6 80.45 13 373.15 373.15 2 304.15 341.07 16.689 5917
7 388. 3 304.15 304.15 Ut. - - 90.233 8891
8 382.785 9 724.45 470.95 14 378.15 422.047 0.21574 4914
9 907.823 7 852.85 719.15 4 378.15 461.513 0.24832 4947
10 33.046 5 836.45 795.45 Ut. - - 5,96E+02 4728
11 520.128 6 795.45 719.85 Ut. - - 0.10496 4790
12 83.898 8 751.85 728.15 Ut. - - 1,75E+02 4654

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13 2. 10 466.75 448.058 4 378.15 379.9865 2,56E+01 4671
14 20.364 19 471.15 425.388 4 378.15 396.849 0.34081 5033
15 26.92 Ut. - - 12 304.15 319.594 4,93E+02 4712
16 756.04 13 373.15 373.15 Ut. - - 67.504 8102
17 140.415 Ut. - - 14 378.15 394.2526 2,98E+02 4679
18 66.411 19 471.15 321.911 Ut. - - 0.55187 5207
19 122.027 Ut. - - 15 304.15 304.15 0.22038 4919
20 395. 3 304.15 304.15 Ut. - - 9.186 8945
21 393. 3 304.15 304.15 Ut. - - 91.395 8929

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Heat Exchanger 1 Heat Exchanger 2

Heat Exchanger 3 Heat Exchanger 4

Heat Exchanger 5 Heat Exchanger 6

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Heat Exchanger 7 Heat Exchanger 8

Heat Exchanger 9 Heat Exchanger 10

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Heat Exchanger 11 Heat Exchanger 12

Heat Exchanger 13 Heat Exchanger 14

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Heat Exchanger 15 Heat Exchanger 16

Heat Exchanger 17 Heat Exchanger 18

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Heat Exchanger 19 Heat Exchanger 20

Heat Exchanger 21

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2.5 Energy Saving and Percent Recovery

Based on the Software Hint it is known that :

• Operating Cost = 98433.9 $ / year

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 • Capital Cost = 67821.3 $ / year
• Total Cost = 166255 $ / year

Of all the methods of solving pinch analysis using the help of HINT software, can be
calculated MER (Maximum Energy Recovery). MER (Maximum Energy Recovery) is the
amount or maximum energy load for heating or cooling that can be reduced after integration
with pinch analysis. Score MER is the difference between the heating or cooling load before
and after integration is done.

Total initial cooling energy = 327,5065 kW

Total initial heating energy = 2771,599 kW
Cooling Duty = 19,9375 kW
Heating Duty = 1948,74 kW
(𝑇𝑜𝑡𝑎𝑙 𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑒𝑛𝑒𝑟𝑔𝑦 + Total initial heating energy )−(𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝐷𝑢𝑡𝑦+𝐻𝑒𝑎𝑡𝑖𝑛𝑔 𝐷𝑢𝑡𝑦)
MER = 2
(2771,599+327,5065 )−(19,9375 +1948,74)
MER = 2

MER = 565,2141 kW
(2771,599 )−(1948.74)
% Energy Recovery for Heating : 𝑥 100 % = 29.6887%
2771,599
(327,5065 )−(19,9375)
% Energy Recovery for Cooling : x 100 % = 93.9123%
327,5065

2 𝑋 𝑀𝐸𝑅 2 𝑋 565,2141 kW
Energy Saving = : Qhot+Qcold 𝑥100% = 2771,599 +327,5065 = 36,47595 %

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 Chapter III
Closing and Conclusion
3.1 Conclusion
1. The Design of Heat exchanger network in this study case involve 13 Sensible stream, 3
latent stream (latent stream 1, latent stream 3w, and latent stream 11w). which contain of 7 Hot
Stream and 6 cold Stream at the start of the design. And after splitting and adding latent stream,
it became 10 Hot Streams and 9 Cold Stream. the design use 8 Coolers, 3 Heaters, and 10 Heat
recovery exchangers. ( total of 21 Heat exchangers, with minimum value: 21).

2. From the analysis using Hint Program, it is estimated that the total heat recovered is 423,3508
kW. And the total area of heat recovery exchanger is 63.785,22 m2 , and the total area of all
heat exchanger is 323.665,2 m2

3. From the analysis using Hint Program, it is estimated that % heat recovery for Heating is
29.69% while for Cooling is 93.91%. and the energy saving is 36,47%

3.2 Suggestion
1. Data on temperature and heat capacity in hot and cold streams are entered carefully.

2. The integration of the heat exchanger is carried out with consideration to prevent this from

happening pinch point crossing and passing the minimum temperature difference

3. Make sure there is no cooler above pinch and heater below pinch

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 Cp ( Stream
Process m (kg/s) Cp.m. (kW/oC) Ti (oC) Tf (oC) Q (kW) type
kJ/kg.oC)
1 0,73 1,31 0,957 26 160 -128,238 COLD

2 1,013 0,439 0,445 203 8 86,775 HOT

3w 4,18 0,521 2,178 26 100 -161,172 COLD

3s 2,09 0,525 1,089 100 203,9 -113,1471 COLD

5 0,82 0,983 0,806 568,3 527,3 33,046 HOT

6 0,9 0,764 0,688 527,3 451,7 52,0128 HOT

7 0,9 0,754 670 584,7 451 90,7823 HOT

8 0,9 0,393 0,354 483,7 460 8,3898 HOT

9 0,84 0,18 0,151 456,3 202,8 38,2785 HOT

10 0,71 0,15 0,107 198,6 28,3 18,2221 HOT

11w 4,18 0,12 0,502 24 29 -2,51 COLD

11s 4,18 0,417 1,743 26 100 -128,982 COLD

13 2,09 0,872 0,872 100 160 -52,32 COLD

Heat load cool load

2771,5991 327,5065 19,9375 Cooling duty
2,7715991 0,327507 1948,74 Heating duty

MER 565,2141
% recovery Heat 29,68897
% recovery cooling 93,91233
Energy Saving 36,47595

Heat load=ABS(SUM(H33;H35;H36;H44;H45)-(70,74+1176+941))

Cool load = =SUM(H34;H37;H38;H39;H40;H41;H42)

MER = ((I33+J33)-(K33+K34))/2

% recovery heat =ABS((I33-K34)/I33)*100

% recovery cool = (J33-K33)/J33*100

% energy saving =((2*J36)/(I33+J33))*100

HOT/COLD=IF(F18>G18;"HOT";"COLD")

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ProcessCp ( kJ/kg.oC) m (kg/s) Cp.m. (kW/oC) Ti (K) Tf (K) Q (kW) Stream type Ti (K) Tf (K)
1 0,73 1,31 0,957 26 160 -128,238 299,15 433,15 COLD 304,15 438,15 0,957 1 1
2 1,013 0,439 0,445 203 8 86,775 476,15 281,15 HOT 471,15 276,15 0,445 2 2
3w 4,18 0,521 2,178 26 100 -161,172 299,15 373,15 COLD 304,15 378,15 2,178 3 3w
3s 2,09 0,525 1,089 100 203,9 -113,1471 373,15 477,05 COLD 378,15 482,05 1,089 4 3s
5 0,82 0,983 0,806 568,3 527,3 33,046 841,45 800,45 HOT 836,45 795,45 0,806 5 4
6 0,9 0,764 0,688 527,3 451,7 52,0128 800,45 724,85 HOT 795,45 719,85 0,688 6 5
7 0,9 0,754 670 584,7 451 90,7823 857,85 724,15 HOT 852,85 719,15 0.679 7 6
8 0,9 0,393 0,354 483,7 460 8,3898 756,85 733,15 HOT 751,85 728,15 0,354 8 7
9 0,84 0,18 0,151 456,3 202,8 38,2785 729,45 475,95 HOT 724,45 470,95 0,151 9 8
10 0,71 0,15 0,107 198,6 28,3 18,2221 471,75 301,45 HOT 466,75 296,45 0,107 10 9
11w 4,18 0,12 0,502 24 29 -2,51 297,15 302,15 COLD 302,15 307,15 0,502 11 10
11s 4,18 0,417 1,743 26 100 -128,982 299,15 373,15 COLD 304,15 378,15 1,743 12 11w
13 2,09 0,417.74 0,872 100 160 -52,32 373,15 433,15 COLD 378,15 438,15 0,872 13 11s

ProcessCp ( kJ/kg.oC) m (kg/s) Cp.m. (kW/oC) Ti (oC) Tf (oC) Q (kW) Heat load cool load
1 0,73 1,31 0,957 26 160 -128,238 2771,5991 327,5065 19,9375
2 1,013 0,439 0,445 203 8 86,775 2,7715991 0,3275065 1948,74
3w 4,18 0,521 2,178 26 100 -161,172
3s 2,09 0,525 1,089 100 203,9 -113,1471 MER 565,21405
5 0,82 0,983 0,806 568,3 527,3 33,046 % recovery Heat 29,68896548
6 0,9 0,764 0,688 527,3 451,7 52,0128 % recovery cooling 93,91233456
7 0,9 0,754 670 584,7 451 90,7823 Energy Saving 36,47594648
8 0,9 0,393 0,354 483,7 460 8,3898
9 0,84 0,18 0,151 456,3 202,8 38,2785 70,74+1176+941 (panas laten reaksi) dimasukkan dalam heat load
10 0,71 0,15 0,107 198,6 28,3 18,2221
11w 4,18 0,12 0,502 24 29 -2,51
11s 4,18 0,417 1,743 26 100 -128,982
13 2,09 0,872 0,872 100 160 -52,32

Process Stream type Ti (K) Tf (K) Cp ( kJ/kg.oC) m (kg/s) Cp.m. (kW/oC) Q (kW)
1 COLD 26 160 0,73 1,31 0,957 -128,238
3w COLD 26 100 4,18 0,521 2,178 424,71
3s COLD 100 203,9 2,09 0,525 1,089 -80,586
11w COLD 24 29 4,18 0,12 0,502 -52,1578
11s COLD 26 100 4,18 0,417 1,743 71,463
13 COLD 100 160 2,09 0,872 0,872 65,9232
2 HOT 203 8 1,013 0,439 0,445 59,4965
5 HOT 568,3 527,3 0,82 0,983 0,806 19,1022
6 HOT 527,3 451,7 0,9 0,764 0,688 174,408
7 HOT 584,7 451 0,9 0,754 0,679 115,6337
8 HOT 483,7 460 0,9 0,393 0,354 -1,77
9 HOT 456,3 202,8 0,84 0,18 0,151 -11,174
10 HOT 198,6 28,3 0,71 0,15 0,107 -6,42
References:

Fenwicks, M., Robert, K., & Alex, A. (2014). Energy Efficiency Analysis Using Pinch
Technology: A Case Study of Orbit Chemicals Industry. IOSR Journal of Mechanical and Civil
Engineering, 11(3), 44–53. https://doi.org/10.9790/1684-11314453