Energy Saving by Optimal Energy Recovery (PINCH)

Energy Saving
by
Optimal Energy Recovery
(PINCH Method)
Standort Ostfriesland
(Emden, 02.04.2003)
Prof. Dr.-Ing. Gerhard Kleemann

Telefon: (04921)807-1519 / Telefax: (04921)807-88-1519
e-mail: kleemann@nwt.fho-emden.de
homepage: http://spot.fho-emden.de/hp/kleemann/kleemann.html
University of Applied Sciences
Oldenburg/Ostfriesland/Wilhelmshaven Energy Recovery Prof. Dr. G. Kleemann
Department of
Applied Natural Sciences PINCH Method Page 1 of 26
Table of Contents
1. Problem Definition and Solving Strategy 2

1.1. The Problem 2
1.2. The Solution 4
2. The Energy Analysis 5
2.1. Designing the Hot and Cold Composite Curves 5
2.2. Determining the Heat Recovery PINCH 6
2.3. Conclusion of the Composite Curve Diagram 7
2.4. The Heat Cascade 9
2.5. The Utility PINCH 12
•
2.6. The T, ? H -Diagram (Grand Composite Curve) 12
3. Designing the Heat Exchanger Network (HEN) 13
3.1. Rules for Designing a HEN 13
3.2. Criteria for the Design at the PINCH 14
3.3. Example for the Design of a HEN 15
4. Simplification of the Designed HEN 17
4.1. Definition of Loops and Paths 17
4.2. Using of Loops and Paths 18
•
5. Utilisation of the T, ? H -Diagram (Grand Composite Curve) 19
6. Integration of Heat Engines, Heat Pumps and Distillation Columns 21
6.1. Integration of a Heat Engine with HEN 21
6.2. Integration of a Heat Pump with HEN 22
6.3. Integration of a Distillation Column with HEN 24
7. Conclusion 26
Appendix
References
Nomenclature
Worksheets 1-5
skript_eng_03-04-05.doc
Department of
1. Problem Definition and Solving Strategy

1.1. The Problem
In many process plants (chemical plants, power stations, air-conditioning) the aim is
to preheat a series of
cold streams
to a certain temperature (feed-in products of distillation columns or vessels, boiler

feed water, fresh air for air conditioning, burner feed air).
Simultaneously produced
hot streams
(distillation and reaction products, exhaust air from air conditioning) must be cooled
down to temperature for further processing or storage.
To solve the recovery problem

external utilities
for heating (steam, gas, oil, electricity) and cooling (cooling air or cooling water) are
provided.
The recovery problem should be solved in such a way, that initially the process
streams themselves are used for preheating and precooling of other streams which
require heating or cooling respectively. The external utilities are only used if, because
of the energy balance or the temperature levels, the available hot and cold streams
are insufficient to achieve the required target temperatures.
Modelling a heat exchanger network (HEN) as shown in Fig. 1-1 is the first step to
solving the problem. The heat exchanger network consists of two parts, the inner
system (IS) and the outer system (OS).
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The cold streams (C) in the inner system are heated up in appropriate heat
exchangers by the hot streams and at the same time the hot streams (H) are cooled
down. Capital costs for the heat exchangers are the consequence.
In the outer system the cold streams are heated by external hot utilities to their target
temperatures and the hot streams require external cold utilities to cool them down to
their target temperatures. Capital costs for the heat exchangers and operating costs
for the external utilities are the consequence. The total costs depend mainly on the
choice of the heat exchange area in the inner system of the heat exchanger network.
An increase of the heat exchange area in the inner system has the following
consequences:
1. Increase of the exchanged energy flow in the IS.

2. Increase of the capital costs in the IS.
3. Decrease of the exchanged energy flow in the OS.
4. Decrease of the capital and energy costs in the OS.
The bigger the heat exchanger area is, the smaller is the temperature difference
between the cold and hot stream. The dependence of the total costs on the minimum
temperature difference (?Tmin) within the inner system is illustrated in Fig. 1-2.
Required is a heat exchanger network with a trade-off between energy and capital
costs, which minimises the
total costs.
Therefore it’s necessary to develop and solve a complex
optimisation problem.
Department of
The secondary conditions of the energy recovery problem are the specific heat
capacities (first law of thermodynamics) and the temperatures of the cold and hot
streams (second law of thermodynamics).
If the target is formulated as a function of capital and energy costs, different

parameters can only be considered secondarily. These parameters are for example:
reliability, size, ease of operation.
1.2. The Solution
To solve the problem it is helpful to divide it into two parts:
Design of the heat exchanger network:
• Design of the structure, determine the couplings of the cold and hot
streams
• Definition of the main dimensions of the heat exchangers
• Preliminary determination of the parameters of the streams such as heat

• •
capacity flow rate ( C p) and stream enthalpy flow ( H ).
Design and scaling of the heat exchanger network:
• Design of all necessary heat exchangers including the exchangers in the

outer and inner system
• Modification of the structure of the heat exchanger network
• Determination of the final parameters of the streams.
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The solution of the first part of the problem – design the heat exchanger network –
can also be done in two stages:
The first stage: Energy analysis of the recovery problem.
The second stage: Structural design of the heat exchanger network.
2. The Energy Analysis
The energy analysis can be done by two equivalent methods:
1. Graphical method: Design of the composite curve.

2. Algorithmical method: Calculation of the heat cascade.
For both methods the following parameters are assumed to be known:
• Inlet temperatures of the hot and cold streams into the system
• Outlet temperatures of the hot and cold streams out of the system
•
• Heat capacity flow rates ( C p / [W/K]) of the hot and cold streams.
2.1. Designing the Hot and Cold Composite Curves
The graphical method consists of designing a
temperature - enthalpy diagram,
which shows all individual cold and hot streams in a single
hot and cold composite curve
respectively.
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The idea is to replace the hot and cold streams by single hot and cold composite
curves separately to carry out the analysis. Within each temperature interval the
streams are combined to produce a composite hot and cold stream. The composite
• •
curve has a C p in all temperature intervals that is the C p - sum of the individual
streams. In any temperature interval, the enthalpy change of the composite curve is
the sum of the enthalpy changes of the individual streams.
The design steps of the hot and cold composite curves are summed up on the
worksheet 1.
An example of determining the curves for two individual streams are shown in Fig.
2-1 and 2-2.
2.2. Determining the Heat Recovery PINCH
The hot and cold composite curves have a fixed position on the temperature axis.
The relative position of the two streams can only be changed by moving them
horizontally relative to one another. This is possible because the reference enthalpy
for the hot stream can be changed independently from the reference enthalpy for the
cold stream. This principle is used to set the heat recovery PINCH.
To determine the PINCH point two working steps are introduced:
1. Targeting the minimum temperature difference ? Tmin
2. Moving the hot and cold composite curves relative to one another (parallel
to the H-axis, no changes on the temperature-axis), until the smallest
vertical distance of the composite curves is reached for a given value of
? Tmin.
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The point, where the composite curves show a minimum temperature difference, is
known as the
heat recovery PINCH or process PINCH.
The PINCH - point has a special significance for the heat recovery. Fig. 2-3 shows a
T, H - diagram representing the heat recovery PINCH.
At the PINCH three temperatures can be seen:
• PINCH temperature of the hot composite curve (TPINCH,H)

→ Temperature of the hot composite curve at the PINCH
• PINCH temperature of the cold composite curve (TPINCH,C)

→ Temperature of the cold composite curve at the PINCH
• PINCH temperature TPINCH

→ Average temperature difference value between the hot and cold
composite curve at the PINCH
2.3. Conclusion of the Composite Curve Diagram
From the T, H - diagram with the PINCH some significant conclusions can be drawn.
The complete system is divided at the PINCH into two independent systems.
Subsystem above the PINCH (in temperature terms):
In the system above the PINCH the energy need of the cold streams is bigger than
the energy supply of the hot streams. That means heat must be received from an
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external hot utility, and no heat is to be removed. The process above the PINCH acts
as a
heat sink.
Subsystem below the PINCH (in temperature terms):
In the system below the PINCH the energy supply of the hot streams is bigger than
the energy need of the cold streams. The system is in heat balance with the
minimum cold utility. No heat is received, but heat is rejected to an external cold
utility. The process acts as a
heat source.
The required minimum duties for the hot and cold utilities (these represent the targets
of the hot and cold utilities) can be read directly from Fig. 2-3.
The enthalpy difference beyond the start of the hot composite curve shows the
•
required duty for the hot utility Q H,min.
The enthalpy difference beyond the start of the cold composite curve indicates the
•
duty for the cold utility Q C,min.
Where the curves overlap heat can be transferred vertically from the hot streams into
•
the cold streams. This represents the maximum heat ( Q Rec,max) which can be
exchanged within the inner system.
• • •
Q H,min, Q C,min and Q Rec,max are functions of the given ? Tmin value.
The results of example 1 are illustrated in Fig. 2-4.
Department of
Three rules are necessary to achieve the energy target set by the composite curves.
These three
PINCH rules
are represented by Fig. 2-5 and 2-6.
The consequences of violating the PINCH-rules are illustrated in the example 2 (Fig.
2-7). In example 1 an extra stream is introduced, which only imports energy below
the PINCH. No changes occurred above the PINCH, but below the PINCH the duty of
the cold utility increased by the extra heat amount of stream 3.
2.4. The Heat Cascade
With the heat cascade method the energy analysis is set by calculating energy
targets.
Starting with the composite curves they are shifted into two directions.
1. First Shift:
The hot composite curve is shifted by –? Tmin/2 under constant enthalpy

conditions.
The cold composite curve is shifted by +? Tmin/2 under constant enthalpy

conditions.
The shifted composite curves now touch at the PINCH (see Fig. 2-9).
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2. Second shift:
The new cold composite curve is now shifted horizontally under constant
enthalpy conditions parallel to the enthalpy-axis. It can be seen that no hot
utility is now used beyond the start of the hot composite curve.
Furthermore the newly repositioned curves show a maximum overlap in
heat transfer and the biggest negative enthalpy difference at the PINCH
(Fig. 2-9).
This basic approach can be developed into a formal algorithm known as

the heat cascade algorithm. On worksheet 4 the calculation is
demonstrated by example 1. At this stage only the principle and the results
will be discussed.
The calculation of the heat cascade is done in four steps. The results are
represented in a table as shown in Fig. 2-10.
Step 1:
Corresponding to the procedure illustrated in Fig. 2-9 the temperatures of the hot
streams are shifted down by –? Tmin/2 and the temperatures of the cold streams are
shifted up by value +? Tmin/ 2. The temperature intervals can now be determined and
the differences are entered into the table.
Step 2:
The next step consists of the heat balance setting for each temperature interval, for
•
which the heat capacity flow rates are added ( C p´s of hot streams count as negative
and those of cold streams positive). The results of the heat balance according to the
equation
• • •
∆ Hi = ( ∑ C pC − ∑ C pH )i * ∆Ti
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can be calculated for each interval. Positive values for heat balances indicate a
deficit and negative values show a surplus.
Step 3:
The heat duty in each interval is solved by removing or adding heat from external
heat sinks or sources (column “Balanced Energy ...”). The heat balance within each
interval allows maximum heat recovery within each interval. However, heat recovery
can also be carried out between intervals. The surplus heat can now be cascaded
down the temperature scale from interval to interval. Looking at the cascade in Fig. 2-
10 it can be seen that some heat flows are negative which is physically impossible.
Heat cannot be transferred up the temperature scale. The point where the biggest
negative heat flow occurs (see column `Cascade 1´) corresponds to the PINCH.
Step 4:
The cascade can be solved by adding the amount of heat with which the energy flow
becomes zero at the PINCH. This does not change the heat balance of the heat
cascade but increases all the heat flows between the intervals (column “Cascade 2”).
At the top of the cascade, the smallest amount of heat can be read off for the hot
utility. The amount of heat to be removed is shown by the value at the bottom of the
cascade. The results agree with the graphical setting of the composite curves as
demonstrated in Fig. 2-4.
The intervals in the column “cascade 3” show the heat surplus and deficit. At the top
a surplus of –115 kW must be added and at the bottom a surplus of –155 kW must
be removed. In many heat cascades like the following the signs of the heat flows
between the intervals are neglected.
The general procedure of the heat cascade can be illustrated in the way that has
been done in Fig. 2-11. The necessary energy flow can be read off between each
temperature interval.
Department of
2.5. The Utility PINCH
The required energy duty, calculated with the heat cascade, which is supplied by
external utilities is added at the highest temperature point. This is obviously not
necessary for every heat recovery case. Energy can be added at a certain
temperature level to satisfy an energy deficit in the corresponding temperature
interval. The amount of heat added can be larger than what is required for this
temperature interval. The larger amount of heat can then be used to cover heat
deficits below.
As shown in Fig. 2-12, the amount of heat added to the cascade reduces the heat
supply at the top of the cascade by the equivalent amount of energy. If the energy
supply is as large as the deficit in the corresponding interval, the heat flow
approaches zero. Such a PINCH is described as a utility PINCH. The actual PINCH
introduced in chapter 2.4 is called process PINCH or heat recovery PINCH.
•
2.6. The T, ? H - Diagram (Grand Composite Curve)
Another possible way to represent the energy situation of the heat recovery problem
•
is the T, ? H - diagram.
•
The T, ? H - diagram shows the heat flow through the process against temperature
and indicates the heat streams at the end of each temperature interval (Fig. 2-13).
The necessity for this diagram will be discussed later.
Department of
3. Designing the Heat Exchanger Network (HEN)
The design of a heat exchanger network requires a set of rules which were
postulated according to the results of the analysis. The application of these rules
leads to a heat exchanger network with maximum heat recovery and minimum use of
hot and cold utilities. A very complex heat exchanger system can be the result. Such
complex systems are characterised by many small duty heat exchangers and many
stream splittings. It is easy to see that a simplification of the designed heat
exchanger system by reducing the number of small heat exchangers and stream
splittings must be carried out under certain considerations.
Note:
Each violation of the PINCH rules leads to increasing operating and capital
costs.
3.1. Rules for Designing a HEN
For an effective design of a HEN some additional tools will be explained first:
• Network design grid

•
• Table of the heat capacity flow rates ( C p - table)
•
The rules for developing the network design grid and C p - table are shown on
worksheet 2.
Fig. 3-1 and 3-2 show an example of a HEN and the corresponding network design
grid.
From the composite plot (or heat cascade) the PINCH temperature can be
determined.
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With this the requirements are fulfilled to start the actual design of the HEN. The
further procedure and rules, which must be strictly applied, are detailed on the
worksheet 3.
3.2. Criteria for the Design at the PINCH
In order to not violate the minimum temperature difference (? Tmin) at the PINCH a
number of criteria must be developed. The following rules are only related to the
• •
number of streams (NH and NC) and to the heat capacity flow rates ( C pH and C pC).
Note that the criteria are postulated for the systems above and below the PINCH
separately. The process should therefore be divided at the PINCH into two
subsystems.
Guidelines above the PINCH:
Cooling above the PINCH is an inappropriate use of utilities.
It follows that all hot streams must be cooled to PINCH temperature by heat
recovery. This means that the same number of cold streams as hot streams must
exist at least to prevent a partial violation of the ? Tmin constraint:
NH ≤ NC .
If this is not the case, then the recovery problem can only be resolved by splitting a
cold stream into two parallel branches.
The minimum temperature difference is set at the PINCH, thus it is only permissible
to couple streams with (see Fig. 3-3):
• •
C pH ≤ C pC .
Department of
Guidelines below the PINCH:
It is not permissible to heat below the PINCH, which means that all cold streams
must be heated to PINCH temperature by heat recovery. Thus the same number of
hot streams must be provided as cold streams at least to prevent any ? Tmin
violations.
NH ≥ NC .
If this is not the case, then the problem can only be resolved by splitting a hot stream
into two branches.
The minimum temperature difference is set at the PINCH, thus it is only permissible
to couple streams with (see Fig. 3-4):
• •
C pH ≥ C pC .
Figs. 3-5 and 3-6 show the stream-splitting algorithms for the design of the HEN
above and below the PINCH. If the design strictly follows the guidelines of the
stream-splitting algorithms, the criteria will be fulfilled.
3.3. Example for the Design of a HEN
The rules for the design of a HEN at the PINCH are listed in Fig. 3-7.
In the following Figs. another example (example 3) and the results are represented
and discussed.
Problem Fig. 3-8
Heat cascade Fig. 3-9
Cp-table Fig. 3-10
HEN design grid Fig. 3-11
HEN flowsheet Fig. 3-12
Department of
The next example (example 4), a frequently discussed case, will be represented in
the next table.
Problem Fig. 3-13
Heat cascade Fig. 3-14
Cp-table Fig. 3-15
As discussed earlier in chapter 3.2 the design of the HEN is started at the PINCH
and is extended separately above and below the PINCH. Although the guidelines for
the design are accurately applied to the network design grid, several equivalent (in
energy terms) HEN are developed.
The Figs. 3-16 and 3-17 show two possibilities for the network design grid above the
PINCH. Picture 3-18 also presents a design, which satisfies the constraint of the
minimal hot utility. The only difference to the design in Fig. 3-17 is that the positions
of the heat exchangers 1 and 2 have been swapped.
It can be seen (Fig. 3-19) that below the PINCH the stream hot 2 has been split into
two branches to satisfy the stream-number rule. The splitting is done in such a way
that the split streams have the same temperature at the mixing point. Two
possibilities are shown in Figs. 3-19 and 3-20.
One of the possible designs for the completed network design grid is illustrated in
Fig. 3-21. The network flowsheet is described in Fig. 3-22.
To decide which design should be realised, other criteria must be considered.
Department of
4. Simplification of the Designed HEN
The application of stream-number and stream-splitting rules to the network design

grid guarantees the use of minimal cold and hot utilities. The optimisation is based on
the redistribution of the exchanger duties. Some exchangers should perhaps be
larger, some smaller, and some perhaps removed from the design altogether. The
objective of the optimisation is to minimize the number of exchangers if the
optimisation sets its duty to zero. It must be noted that this optimisation includes
possible constraint violations in terms of ? Tmin or external heating or cooling duties.
To simplify the exchanger network paths and loops must be introduced:
4.1. Definition of Loops and Paths
A loop begins and ends at the same point within the network design grid. A loop
leads from one exchanger back to the same exchanger, possibly passing through
several other exchangers. In Fig. 4-1 (example 4) such a loop is determined and
highlighted. Its significant feature is that heat can be shifted around the loop. The
heat duty is subtracted from one exchanger and is added to another one
simultaneously. If more than two exchangers are included in a loop the addition and
subtraction of the heat duty must be done alternately.
The dotted line in Fig. 4-2 designates a second loop. It can be seen that the loop
includes two heaters in a row. To move heat duty within this loop, the heat must be
subtracted from one heater and added to the other one.
A path is a distinct line between a hot utility and a cold utility passing through one or
more heat exchangers. In other words the path links a heater with a cooler within the
network design and can be used to balance the energy duty.
The heat duty is moved along the path possibly being added to the heater,
subtracted from the next exchanger again and finally being added to a cooler.
Fig. 4-3 illustrates a path in the network design grid for example 4.
Department of
4.2. Using of Loops and Paths
The loop concept is now used to simplify the network design grid in example 4. The
heat duty from heat exchanger 4 is completely moved to exchanger 1, which means
that exchanger 4 can be removed from the design. Therefore the specified minimum
temperature difference ? Tmin is violated (Fig. 4-4). In many practical cases the
resulting optimised network design can be now applied without any other
considerations.
The movement of the heat duty along the path can be used for example to reset the
violation of the ? Tmin value. With the export of 4 kW at heat exchanger 1 the specified
? Tmin of 20 K is reached again. However the 4 kW subtracted from exchanger 1 must
be added along the path between the heater and cooler as shown in Fig. 4-5.
Department of
•
5. Utilisation of the T, ? H -Diagram (Grand Composite Curve)
•
The utilisation of the T, ? H -diagram in chapter 2.6 introduced can be best explained
by an example (example 5).
•
The problem, the stream table, the heat cascade, the listing of the results, the C p -
table, the network design grid and the network flow sheet are shown in Figs. 5-1 to 5-
•
7. The construction of the T, ? H -diagram (Fig. 5-8) was completed with the help of
the temperature and enthalpy data taken from the heat cascade. The diagram has a
special significance. At higher temperatures the curve returns to the T-axis. This
indicates that the external hot utility must not necessarily be placed at the highest
temperature level. The vertical dotted line (beginning near 245.0 °C) shows the same
•
? H - values at a temperature of 145.6 °C as just below 245.0 °C. This means that
the whole duty of the hot utility can be imported at the temperature of 145.6 °C.
•
With the altered heat import at a lower temperature the head cascade and T, ? H -
diagram shows a new profile as illustrated in Figs. 5-9 and 5-10. A new PINCH can
now be introduced, the utility PINCH.
With this utility PINCH and the process PINCH the heat exchanger network can be
developed. Figs. 5-11 and 5-12 show two possibilities for the design above the
PINCH. The left segment now needs no external utility, but instead the segment near
the process PINCH must be provided by the 1.67 MW utility. The only difference
between the designs in Figs. 5-11 and 5-12 is the stream splitting above and below
the utility PINCH.
In addition in Fig. 5-11 a loop was determined to simplify the design. The small heat
exchanger with a duty of 0.31 MW can be added to the 1.619 MW exchanger. Thus
new temperatures at the inlets of the heater and exchanger must be set, but
simultaneously the heat duties of these two utilities remain unchanged. The mixing
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temperature at the splitting point is 143.3 °C (Fig. 5-13).
The new ? Tmin of 7.3 K, which was the result of the exchanger removal must now be
considered.
If the minimal temperature difference is acceptable the resulting heat exchanger

network is much simpler than the one before. Above the utility PINCH only two
streams exist and the original splitting can be removed.
Department of
6. Integration of Heat Engines, Heat Pumps and Distillation

Columns
6.1. Integration of a Heat Engine with HEN
In this chapter the integration of a heat engine into the heat exchanger network
(HEN) is discussed.
Beginning with a simple heat engine, the energy balance, schematic, working
procedure of a simple Clausius-Rankine steam process and the corresponding T, s-
diagram are illustrated in the Figs. 6-1 to 6-4.
The PINCH rules are useful tools to examine the integration of heat engines.
Coupling above the PINCH:
Corresponding to Fig. 6-5 the heat engine exports heat at the highest HEN
temperature (exhaust heat). The heat engine loses no energy to the environment and
in terms of the HEN no additional hot utility is necessary. Integration in this way is
much more effective than the two separate systems.
The heat export of the heat engine can also take place at various temperatures
above the PINCH. As can be seen in Fig. 6-6 the heat engine exploits the
temperature differences that exists between the temperature intervals and imports
only the deficit which is needed to satisfy the energy balance.
Applications solved in this way lead to energy savings.
Coupling below the PINCH:
Integrating a heat engine below the PINCH is only advantageous if the surplus of one
•
or several temperature intervals can be used to produce shaftwork ( W ) (Fig. 6-7).
The industrial application of this coupling is generally very difficult because the
conversion of heat at low temperature into shaftwork involves technical problems.
Department of
Coupling across the PINCH:
Integration of the heat engine across the PINCH as shown in Fig. 6-8 is
counterproductive and violates the PINCH rules (no heating below the PINCH and no
•
heat transfer across it). The process still requires Q H,min and the heat engine
performs no better than if operated stand-alone.
6.2. Integration of a Heat Pump with HEN
This chapter will be discussed how a heat pump can be integrated into the heat
exchanger network (HEN).
Beginning with a simple heat pump, the energy balance, schematic, working
procedure and the corresponding T, s-diagram are illustrated in the Figs. 6-9 to 6-12.
The PINCH rules seem once again to be a useful tool to discuss the coupling of the
heat pump with the HEN.
Integration without crossing the PINCH is demonstrated in Fig. 6-13. This

arrangement exports heat at a lower temperature (above PINCH) to the heat pump,
• •
the converted energy ( Q 1 + W ) is imported back into the system at a higher
temperature. The export of heat from a lower temperature violates a PINCH rule (no
cooling above the PINCH). With the integration of the heat pump, some energy,
which is imported back at higher temperature, is replaced by shaftwork.
Looking at the energy balance formally, no disadvantage occurs, but the replacement
of heat by electrical energy is a disadvantage for economic reasons.
Department of
Another way to integrate a heat pump without crossing the PINCH is shown in Fig. 6-
14. This method is uneconomical. Importing shaftwork as heat at a higher
temperature violates a PINCH rule (no heating below PINCH), and turns power into
waste heat.
Heat pump integration across the PINCH is illustrated by Fig. 6-15 and demonstrates
a genuine saving of energy.
•
Below the PINCH surplus heat is exported (cooling Q ) and finally imported back into
• •
the system (heating Q + W ) above the PINCH. Both steps conform to the PINCH
rules.
• •
For the system above the PINCH the hot utility is reduced by the value Q + W and
•
the cold utility below PINCH by Q . The power W (electrical energy) has to be
applied.
The placement of a heat pump against relatively high temperature differences in a

HEN must be compensated by power. This indicates once again the technical
problem of finding an appropriate heat pump, which meets such demands.
Additionally in many cases the heat pump efficiency should be checked to see, if
integration is economically worthwhile the effort.
Department of
6.3. Integration of a Distillation Column with HEN
Finally, the integration of a distillation column (DC) into the heat exchanger network
(HEN) will be discussed. A simple distillation column (Fig. 6-16) with reboiler and
condenser is used to explain the integration.
•
As can be seen in Fig. 6-17 the column imports Q reb from the process above the
•
PINCH and exports the heat Q cond to the column at a lower temperature but still
above the PINCH. At the higher temperature interval of the heat cascade the
• •
difference Q reb – Q cond must be added to satisfy the column.
It is not necessary to take the heat for the reboiler from the process, it can also be
imported from an external utility. The question is, at which temperature the heat from
the condenser is to be supplied. If the condenser temperature lies above the PINCH
temperature, the condenser must be integrated above the PINCH - it acts as a heater
(Fig. 6-18). If the condenser temperature lies below PINCH temperature, integration
does not make much sense (no heating below PINCH).
• •
A distillation column below the PINCH imports Q reb from the HEN and exports Q cond
•
to the HEN again. At a lower temperature, where Q cond is reimported, the difference
• •
Q cond – Q reb must be supplied by external utilities. As long as this temperature
difference is relatively small, the integration of the DC with the process is
advantageous. The column then works nearly with practically no additional energy
(Fig. 6-19).
There is no need for the column to export the heat back to the process, instead the
heat can be saved for other recovery purposes (no heating below PINCH). The
question here is, at which temperature the reboiler heat is needed. If it is below
Department of
PINCH temperature the reboiler must be integrated and would act as cooling (see
Fig. 6-20).
Fig. 6-21 clearly indicates that the integration of DC across the PINCH violates the
PINCH rules in terms of no heating below and no cooling above the PINCH.
The question, how heat engine, heat pump and column can be integrated has only
been discussed from the energy point of view. Of course some other criteria must be
considered such as measurement, control and regulation technology. A breakdown
of a single part of the system causes a failure of the whole system.
Department of
7. Conclusion
The design of heat exchanger networks supported by the PINCH - method leads in
all cases to minimal cold and hot utility duties.
The result depends on the choice of the minimum temperature difference (? Tmin),
which must be determined at the beginning for each problem to be solved.
HEN designs can be supported by software based on composite curves and

cascades. When using such software it must be noted that knowledge of the
schematic and solving procedure are essential to achieve appropriate results.
If the resulting exchanger design becomes too complex some additional criteria can
be introduced to simplify the concept. Most of the simplifying procedures result in an
increased utility duty.
Generally the design of the heat exchanger network is a function of operating and
capital costs. Depending on which target – minimum operating or capital costs - is
achieved, the design can only be proceeded as a function of operating costs or
capital costs.
By extending the PINCH-method, the analysis is suited to optimising complex

process plants, which can also possibly be extended by coupling with public supply
heating systems.
The integration of heat pumps can be applied without any problems.
The PINCH - method represents an effective tool to analyse existing or planned

energy systems.
Department of
Applied Natural Sciences PINCH Method References
A. General Reports
Linnhoff, B:
Use Pinch Analysis to Knock Down Capital Costs and Emissions
Chem. Engng. Prog. (1994) 8, S.33-37
Smith, R.:
Chemical Process Design
McGraw Hill, 1995, S.159-213
B. Reports
Linnhoff, B. and Flower, J.R.:

Synthesis of Heat Exchanger Networks
Part 1: Systematic Generation of Energy Optimal Networks
AIChE J. 24(1978) 4, 633-642
Part 2: Evolutionary Generation of Networks with Various Criteria of Optimality
AIChE J. 24 (1983) 5, S. 745-763
Linnhoff, B. and Hindmarsh, E.:

Pinch Design Method of Heat Exchanger Networks
Chem. Eng. Sc. 38 (1983) 5, S. 742-748
Townsend, D. W. and Linnhoff, B.:

Heat and Power Networks in Process Design
Part 1: Criteria for Placement of Heat Engines and Heat Pumps in Process Networks
AIChE 29 (1983) 5, S. 742-748
Part 2: Design Procedure for Equipment Selection and Process Matching
AIChE 29 (1983) 8, S. 748-771
Linnhoff, B., Dunford, H. and Smith, R.:

Heat Integration of Distillation Columns into Overall Process
Chem. Eng. Sc. 38 (1983) 8, S. 1175-1188
Tjoe, T. and Linnhoff, B.:

Using Pinch Technology for Process Retrofit
Chem. Eng. (1986) Apr. 28. S. 47-60
C. Software
ASPENPINCH (Aspen Technology, Inc., Cambridge, U.S.A.)
SUPERTARGET (Linnhoff March International, U.S.A.)
HEATNET (National Engineering Laboratory, East Kilbride, Scotland)
HEXTRAN (Simulation Sciences, Brea, CA)

references_03-04-02.doc
Department of
Applied Natural Sciences PINCH Method Nomenclature
Nomenclature
Symbol Quantity Unit

αi tube side heat transfer coefficient of a stream kW m-2 K-1
αa shell side heat transfer coefficient of a stream kW m-2 K-1
k overall heat transfer coefficient kW m-2 K-1
A heat exchanger area m2
cp specific heat capacity kJ kg-1K-1
•
Cp heat capacity flowrate kW K-1
Tbig big temperature difference °C, K
∆Tcold temperature difference of the cold streams °C, K
∆Thot temperature difference of the hot streams °C, K
∆Tm logarithmic mean temperature difference (LMTD) °C, K
∆Tmin minimum temperature difference °C, K
∆Tsmall small temperature difference °C, K
h specific enthalpy kJ kg-1
•
H enthalpy flow rate kW
m mass flow rate kW
•
Q heat duty kW
•
Q a,sink additional heat sink above the pinch kW
•
Q a,source additional heat source below the pinch kW
•
Q C,min minimum cold utility at the cold end, kW
target for cold utility
•
Q H,min minimum hot utility at the hot end, kW
target for hot utility
•
Q Rec,max target for maximum heat recovery kW
•
Q pinch heat transfer across the pinch kW
T temperature °C, K
TC cold-stream temperature °C, K
TH hot-stream temperature °C, K
TS stream supply temperature °C, K
TT stream target temperature °C, K
nomenclature_03-04-02.doc
List of Important
Symbols at the Heat Exchanger
Quantity Symbol Unit
Mass flow rate m kg / h
Specific enthalpy h kJ / kg
Specific heat capacity cp kJ / (kg * K)
Enthalpy flow rate H=m*h kJ / h or kW
Heat flow rate Q = m * c p * ∆T kW

Q = m * ∆h = ∆H kW
Q = k * A * ∆Tm kW
Heat capacity flow Cp = m * cp kW / K

rate
H
Cp = kW / K
T
University of PROF. DR.

Applied Sciences Energy Recovery KLEEMANN
Emden
Temperature Differences
at the Heat Exchanger
T
T1
∆Thot ∆Tsmall
T2 ∆Tm T4
∆Tbig
∆Tcold
T3
H
∆Thot temperature difference of the hot stream
∆Tcold temperature difference of the cold stream
∆Tbig big temperature difference
∆Tsmall small temperature difference
∆Tm logarithmic mean temperature difference
∆Tmin minimum temperature difference

Emden
Heat Exchanger Network Design
Hot 1 Hot 2 Hot 3 Hot m
Cold 1
Cold 2
Cold n
II
I: Inner system m hot streams

II: Outer system n cold streams
Emden
1-1
Cost Optimum of Heat Exchanger Networks
Total cost
Optimum
Annual cost
Operating cost
Capital cost
∆Tmin

Emden
1-2
Problem Table for Example 1
capacity flow rate

Supply enthalpy
Target enthalpy
Stream
temperature
temperature
number
and
flow rate
flow rate
Supply
Target
type
Heat
T1 T2 H1 H2 Cp
[°C] [°C] [kW] [kW] [kW/K]
Hot 1 200 100 200 100 1
Hot 2 150 30 300 60 2
Cold 1 50 250 200 500 1.5
Specified minimum temperature difference: ∆Tmin = 10K

Emden
2-1
Constructing the Composite Curves
T / °C
Hot composite curve

200
Hot 1
150
Hot 2
100
50
30
60 100 200 200

240 300 390 400 440 H / kW

Emden
2-2
T, H - Plot Including the PINCH
T / °C QH,min
∆Tmin = 10 K
250
200
PINCH Composite curve of
the cold streams
150
Composite curve
of the hot streams ∆T min
100
50
30 Q C,min Q Rec,max
60 100 200 300 400 H / kW

Emden
2-3
T / °C
E xa m ple 1
Q H ,m in
∆Tmin = 10 K 11 5 k W
250
200
Composite curve of
Hot 1 the hot streams
150
Cold 1 = Composite curve of
the cold streams
100
Hot 2
50
30 155 kW
QC,min Q Rec,max = 185 kW
60 100 200 300 400 500 H / k W
2-4
Heat Flows in the HEN
T
Q H,min + Q a,sink + QPINCH
Qa,source
Heat
sink
QPINCH
Heat Qa,sink
source
Q C,min + Q a,source + Q PINCH
Q H,min minimum hot utility

Q a,sink additional heat sink above the PINCH
Q PINCH heat transfer across the PINCH

Qa,source additional heat source below the PINCH
Q C,min minimum cold utility

Emden
2-5
PINCH Rules
- Do not use hot utilities below the PINCH
- Do not use cold utilities above the PINCH
- Do not transfer heat across the PINCH

Emden
2-6
capacity flow rate

Supply enthalpy
Target enthalpy
Stream
temperature
number temperature
and
flow rate
flow rate
Supply
Target
type
Heat
T1 T2 H1 H2 Cp
[°C] [°C] [kW] [kW] [kW/K]
Hot 1 200 100 200 100 1
Hot 2 150 30 300 60 2
Hot 3 100 50 400 300 2
Cold 1 50 250 200 500 1.5

Emden
2-7
Exam ple 2
T / °C Q H,m in = 11 5 kW
∆Tmin = 10 K
250
200
Composite curve of
the hot streams
150
10 K
100
Composite curve of
the cold streams
50
30
Q C,min = 255 kW
100 200 300 400 500 H / kW
2-8
Graphical Setting of PINCH-Facility
Maximum Q H,min
heat overlap
T
+ ∆Tmin / 2
- ∆Tmin / 2 ∆Tmin
Q C,min PINCH for ∆Tmin

Emden
2-9
Heat Cascade (Example 1)
( Please Note: Hot and cold streams must be shifted by ∆Tmin /2. Hot streams: - ∆Tmin /2. Cold streams: + ∆Tmin /2. )
Balanced energy
Surplus
Σ Cp i
Deficit /
Hi
number
Interval
within the interval
Streams Cascade 1 Cascade 2 Cascade 3
[K] [ kW/K ] [ kW ]
Hi
0 115 - 115
T1 = 255 °C
1 60 +1.5 + 90 D - 90 - 90 - 90 + 90
- 90 25 - 25
T2 = 195 °C
2 50 +0.5 + 25 D - 25 - 25 - 25 + 25
- 115 0 0
T3 = 145 °C
3 50 -1.5 - 75 S + 75 + 75 + 75 - 75
- 40 + 75 - 75
T4 = 95 °C
4 40 -0.5 - 20 S + 20 + 20 + 20 - 20
- 20 + 95 - 95
T5 = 55 °C
5 30 -2.0 - 60 S + 60 + 60 + 60 - 60
+ 40 + 155 - 155
T6 = 25 °C
6
T7 = °C
1.5 -1 -2
Q H, min = 115 kW Q C,min = 155 kW TPINCH = 145 °C TPINCH, H = 150 °C TPINCH,C = 140 °C
2 -10
Heat Cascade
Q1 = Q H,min
Interval 1
Q2
Qp-1
Interval p-1
PINCH-
Temperature
Qp = 0
Interval p
Qp+1
Qn
Interval n
Qn+1 = QC,min

Emden
2 - 11
The Utility - PINCH
QH,min - Qx QH,min - Qy
QUP = 0 Utility
Qx PINCH
Qy
Process
PINCH
QPP = 0 QPP = 0
QC,min QC,min
Emden
2 - 12
Grand Composite Curve (Example 1)
T
255°C
115 kW
195°C
25 kW
145°C
75 kW
95°C
95 kW
55°C
155 kW
25°C ∆H
Emden
2 - 13
Flowsheet
hot 1 hot 2 H
200°C 360°C
cold 120°C 380°C

Cp = 1,0 kW/K
1
210 kW 50 kW
cold 20°C 200°C

Cp = 1,5 kW/K
2
100 kW 170 kW
C
116 kW
80°C 170°C
C p = 1,8 C p = 2,0
kW/K kW/K
H: Hot utility
C: Cold utility

Emden
3-1
HEN Design Grid
200°C 144°C 80°C

hot 1 C 1,8 kW/K
116 kW
360°C 255°C 170°C

hot 2 2,0 kW/K
380°C 330°C 120°C

H cold 1 1,0 kW/K
50 kW 210 kW
200°C 87°C 20°C

cold 2 1,5 kW/K
170 kW 100 kW
Cp in kW/K
Q in kW
H: Hot utility
C: Cold utility

Emden
3-2
Pinch Match above the PINCH
T PINCH
CpH
CpC ∆Tmin
CpH < Cp C

Emden
3-3
Pinch Match below the PINCH
T
PINCH
Cp H
∆Tmin
Cp C
CpH > Cp C

Emden
3-4
Design Procedure above the PINCH
Start
NH < NC
yes no
Cp H Cp C Split a cold stream

- for every PINCH match
- for every hot stream
yes no
Further stream splitting

is required
feasible design

Emden
3-5
Design Procedure below the PINCH
Start
NH > NC
yes no
Cp H Cp C Split a hot stream

- for every PINCH match
- for every cold stream
yes no
Further stream splitting

is required
feasible design

Emden
3-6
Rules for the
Design of a Heat Exchanger Network
Rule 1: Split the process into two independent subsystems

(one below the PINCH and one above the PINCH).
Rule 2: Start the design at the PINCH.
Rule 3: Combine the streams in the order of decreasing

heat capacities.
Rule 4: Choose the heat exchanger with a heat duty as

large as possible (tick off rule).
Rule 5: Continue with the hot and cold utilities.

Emden
3-7
capacity flow rate

Stream
temperature
temperature
number
and
Supply
Target
type
Heat
T1 T2 Cp
[°C] [°C] [kW/K]
Hot 1 170 60 3.0
Hot 2 150 30 1.5
Cold 1 20 135 2.0
Cold 2 80 140 4.0

Emden
3-8
Balanced energy
number
Interval
Σ Cp i Hi
Surplus
Deficit /
Streams within the interval
Cascade 1 Cascade 2 Cascade 3
[K] [ kW/K ] [ kW ] ∆Hi
165 °C 0 20 -20
T1 =
1 20 - 3.0 - 60 S 60 60 60 - 60
60 80 -80
T2 = 145 °C
2 5 - 0.5 - 2.5 S 2.5 2.5 2.5 - 2.5
T3 = 62.5 82.5 -82.5
140 °C
3 55 1.5 82.5 D - 82.5 - 82.5 - 82.5 82.5
T4 = - 20 0 0
85 °C
4 30 - 2.5 - 75 S 75 75 75 - 75
T5 = 55 75 -75
55 °C
5 30 0.5 15 D - 15 - 15 - 15 15
T6 = 40 60 -60
25 °C
6
T7 = °C
2.0 4.0 -3.0 -1.5
Q H, min = 20 kW Q C, min = 60 kW TPINCH = 85°C TPINCH, H = 90°C TPINCH, C = 80°C

3-9
Cp -Table above the PINCH (Example 3)
Cp H Cp C
Hot 1 3 4 Cold 2
Hot 2 1.5 2 Cold 1
Cp -Table below the PINCH (Example 3)
Cp H Cp C
Hot 1 3 2 Cold 1
Hot 2 1.5

Emden
3 - 10
HEN Design Grid (Example 3)
Hot 1 170°C 90°C 90°C 60°C

3.0
Hot 2 150°C 90°C 90°C 70°C 30°C

1.5
C
60
135°C 125°C 80°C 80°C 35°C 20°C Cold 1

H 2.0
20 90 90 30
140°C 80°C Cold 2

4.0
240
Cp in kW/K
Q in kW
H: Hot utility
C: Cold utility

Emden
3 - 11
HEN Flowsheet (Example 3)
Hot 2 Hot 1
150°C 170°C
140°C 240 kW
80°C
Cold 2
90°C
90 kW 90 kW 30 kW
135°C
H 125°C 80°C 35°C 20°C
Cold 1
20 kW
90°C 60°C
70°C
C 60 kW
60°C 30°C
H: Hot utility
C: Cold utility

Emden
3 - 12
Problem Table for Example 4 1 )
capacity flow rate

Stream
temperature
temperature
number
and
Supply
Target
type
Heat
T1 T2 Cp
[°C] [°C] [kW/K]
Hot 1 150 60 2
Hot 2 90 60 8
Cold 1 20 125 2.5
Cold 2 25 100 3.0
1) Linnhof, B. and Hindmarsh, E.: Chem. Eng. Sci. 38 (1983) 5, 745-763

Emden
3 - 13
Balanced energy
number
Interval
Σ Cp i Hi
Surplus
Deficit /
within the interval
Streams Cascade 1 Cascade 2 Cascade 3
[K] [ kW/K ] [ kW ] ∆Hi
0 107.5 -107.5
T1 = 140 °C
1 5 - 2.0 - 10 S 10 10 10 -10
10 117.5 -117.5
T2 = 135 °C
2 25 0.5 12.5 D - 12.5 -12.5 -12.5 12.5
- 2.5 105 -105
T3 = 110 °C
3 30 3.5 105 D - 105 -105 -105 105
- 107.5 0 0
T4 = 80 °C
4 30 - 4.5 - 135 S 135 135 135 -135
27.5 135 -135
T5 = 50 °C
- 82.5 - 82.5 82.5
5 15 5.5 82.5 D - 82.5
- 55 52.5 -52.5
T6 = 35 °C
6 5 2.5 12.5 D - 12.5 - 12.5 -12.5 12.5
- 67.5 40 -40
T7 = 30 °C
2.5 3.0 -2.0 -8.0
Q H, min = 107.5 kW Q C, min = 40 kW TPINCH = 80°C TPINCH, H = 90°C TPINCH, C = 70°C

3 - 14
Cp H Cp C
Hot 1 2 3 Cold 2
2.5 Cold 1
Cp H Cp C
Hot 2 8 3 Cold 2
Hot 1 2 2.5 Cold 1

Emden
3 - 15
HEN Design Grid
above the PINCH (Example 4, Variation 1)
Hot 1 150°C 90°C

2.0 1
125°C 118°C 70°C Cold 1

H 2.5
17.5 120
100°C 70°C Cold 2

H 3.0
90
Cp in kW/K
Q in kW
H: Hot utility

Emden
3 - 16
HEN Design Grid
Hot 1 150°C 135°C 90°C

2.0 2 1
125°C 82°C 70°C Cold 1

H 2.5
107.5 30
100°C 70°C Cold 2

3.0
90
Cp in kW/K
Q in kW
H: Hot utility

Emden
3 - 17
HEN Design Grid
Hot 1 150°C 105°C 90°C

2.0 1 2
125°C 82°C 70°C Cold 1

H 2.5
107.5 30
100°C 70°C Cold 2

3.0
90
Cp in kW/K
Q in kW
H: Hot utility

Emden
3 - 18
HEN Design Grid
below the PINCH (Example 4, Variation 1)
Hot 1 90°C 80°C 60°C

2.0 3 C
40
Hot 2 90°C 3.5 60°C

8.0 2
4.5
1
70°C 28°C 20°C Cold 1
2.5
105 20
70°C 25°C Cold 2

3.0
135
Cp in kW/K
Q in kW
C: Cold utility

Emden
3 - 19
HEN Design Grid
below the PINCH (Example 4, Variation 2)
Hot 1 90°C 80°C 60°C

2.0 3 C
40
Hot 2 90°C 3.834 60°C

8.0 2
4.166
1
70°C 20°C Cold 1

2.5
125
70°C 31,7°C 25°C Cold 2

3.0
115 20
Cp in kW/K
Q in kW
C: Cold utility

Emden
3 - 20
Hot 1 150°C 90°C 80°C 60°C

2.0 1 4 C
40
Hot 2 90°C 3.5 60°C 60°C

8.0 3
4.5 60°C
2
125°C
70°C 28°C 20°C Cold 1
H 2.5
17.5 120 105 20
100°C
70°C 25°C Cold 2
H 3.0
90 135
Cp in kW/K
Q in kW
H: Hot utility
C: Cold utility

Emden
3 - 21
Hot 1 Hot 2
150°C 90°C
120 kW 90°C 20 kW
125°C 118°C 70°C 105 kW 20°C
H 28°C
Cold 1
17.5 kW
90°C 60°C 80°C
90°C
135 kW
100°C 70°C 25°C
H Cold 2
90 kW 60°C
C 40 kW
60°C 60°C
H: Hot utility
C: Cold utility
Emden
3 - 22
Definition of Loops
Hot 1 150°C 90°C 80°C 60°C

2.0 1 4 C
40
Hot 2 90°C 3.5 60°C 60°C

8.0 3
4.5 60°C
2
125°C
118°C 70°C 28°C 20°C Cold 1
H 2.5
17.5 120 105 20
100°C
70°C 25°C Cold 2
H 3.0
90 135
Cp in kW/K
Q in kW
H: Hot utility
C: Cold utility
Emden
4-1
Definition of Loops
Hot 1 150°C 90°C 80°C 60°C

2.0 1 4 C
40
Hot 2 90°C 3.5 60°C 60°C

8.0 3
4.5 60°C
2
125°C
118°C 70°C 28°C 20°C Cold 1
H 2.5
17.5 120 105 20
100°C
70°C 25°C Cold 2
H 3.0
90 135
Cp in kW/K
Q in kW
H: Hot utility
C: Cold utility
Emden
4-2
Definition of Paths
Hot 1 150°C 90°C 80°C 60°C

2.0 1 4 C
40
Hot 2 90°C 3.5 60°C 60°C

8.0 3
4.5 60°C
2
125°C 118°C 70°C 28°C 20°C Cold 1

H 2.5
17.5 120 105 20
100°C
70°C 25°C Cold 2
H 3.0
90 135
Cp in kW/K
Q in kW
H: Hot utility
C: Cold utility
Emden
4-3
Simplification of the HEN
Hot 1 150°C 80°C 60°C

2.0 1 C
40
Hot 2 90°C 3.5 60°C

8.0 3
4.5
2
125°C
118°C 62°C 20°C Cold 1
H 2.5
17.5 140 105
100°C
70°C 25°C Cold 2
H 3.0
90 135
No Change of H and C (Loop), HEN without Heat Exchanger Number 4.
Consequence: - Violation of the ∆Tmin - Condition

- ∆Tmin = 18 K
Cp in kW/K
Q in kW

Emden
4-4
Simplification of the HEN
Hot 1 150°C 82°C 60°C

2.0 1 C
40 + 4 = 44
Hot 2 90°C 3.5 60°C

8.0 3
4.5
2
125°C
116.4°C 62°C Cold 1
H 2.5
17.5 + 4 = 21,5 140 - 4 = 136 105
100°C
70°C Cold 2
H 3.0
90 135
Restore the ∆Tmin Constraint (∆Tmin = 20 K), HEN without Heat Exchanger Number 4.
Consequence: - Increasing hot utility duty by 4 kW

- Increasing cold utility duty by 4 kW
Cp in kW/K
Q in kW
Emden
4-5
Distillation Column -
Separation of Naphtha and LGO (Example 5)
100°C
OP
40 °C 40 °C
LN
50 t/h 50 t/h
160°C 40 °C
HN
50 t/h
25 °C 185°C
F
170 t/h
F : Feed Product
LN : Light Naphtha 250°C 50 °C
LGO
HN : Heavy Naphtha 70 t/h
LGO : Light Gasoil
OP : Overhead Product

Emden
5-1
capacity flow rate

temperature
temperature
Stream Stream
number type Supply
Target
Heat
T1 T2 Cp
[°C] [°C] [MW/K]
LGO Hot 1 250 50 0.047
HN Hot 2 160 40 0.032
OP Hot 3 100 40 0.216
F Cold 1 25 185 0.112

Emden
5-2
Balanced energy
number
Σ Cp i
Interval
Hi
Surplus
Deficit /
Streams within the interval Cascade 1 Cascade 2 Cascade 3
[K] [ kW/K ] [ kW ] Hi
3
10 103 0 1.670 -1.670
T1 = 245 °C
0.112
1 55 - 0.047 - 2.585 S 2.585 2.585 2.585 - 2.585
2.585 4.255 -4.255
T2 = 190 °C
2 35 0.065 2.275 D - 2.275 - 2.275 - 2.275 2.275
0.310 1.980 -1.980
T3 = 155 °C
3 60 0.033 1.980 D - 1.980 - 1.980 - 1.980 1.980
- 1.670 0 0
T4 = 95 °C
4 50 - 0.183 - 9.150 S 9.150 9.150 9.150 - 9.150
7.480 9.150 -9.150
T5 = 45 °C
1.360 1.360 - 1.360
5 10 - 0.136 - 1.360 S 1.360
8.840 10.510 -10.510
T6 = 35 °C
- 0.047
- 0.032
- 0.216
6 5 0.112 0.560 D - 0.560 - 0.560 - 0.560 0.560
T7 = 8.280 9.950 -9.950

30 °C
3 3
Q H, min = 1.670 10 kW Q C, min = 9.950 10 kW TPINCH = 95°C TPINCH, H = 100°C TPINCH, C = 90°C
5-3
Results from the Heat Cascade
for Example 5
∆Tmin = 10 K (specified)
Q H, min = 1.670 MW
Q C, min = 9.950 MW
T PINCH, H = 100 °C
T PINCH, C = 90 °C
T PINCH = 95 °C

Emden
5-4
Cp H Cp C
Hot 1 0.047 0.112 Cold 1
Hot 1 0.032
Cp H Cp C
Hot 3 0.216 0.112 Cold 1
Hot 1 0.047
Hot 2 0.032

Emden
5-5
Hot 1 250°C 100°C 100°C 50°C

0.047 C
2.35
Hot 2 160°C 100°C 100°C 40°C

0.032 C
1.92
185°C 0.074 Hot 3 100°C 66.3 40°C

0.216 C
7.05 5.68
185°C 140.5°C 0.038 90°C 25°C Cold 1

H 0.112
1.67 1.92 7.28
Cp in MW/K
Q in MW
C: Cold utility
H: Hot utility
Emden
5-6
Hot 2 Hot 1 Hot 3
160°C 250°C 100°C
7.05 MW
185°C
100°C 25°C
90°C 7.28 MW
Cold 1
1.67 MW 1.92 MW
185°C
H 66.3°C
140.5°C
100°C
1.92 MW C C 2.35 MW C 5.68 MW
40°C 50°C 40°C
C: Cold utility
H: Hot utility
Emden
5-7
T
°C
300
245 1.67 MW
200
190 4.225 MW
155 1.98 MW
145.6°C
100
95
9.15 MW
45
35 10.51 MW
30 9.95 MW
2 4 6 8 10 12 ∆H
MW
Emden
5-8
T
°C
300
245 1.67 MW
200
190 4.225 MW
155 1.98 MW Utility

145.6°C PINCH
100 Process
95 PINCH
9.15 MW
45
35 10.51 MW
30 9.95 MW
2 4 6 8 10 12 ∆H
MW
Emden
5-9
T
°C
300
245 1.67 MW
200
190 4.225 MW
155 1.98 MW Utility

145.6°C PINCH
100 Process
95 PINCH
9.15 MW
45
35 10.51 MW
30 9.95 MW
2 4 6 8 10 12 ∆H
MW
Emden
5-9
Hot ultility at
Top of Cascade Hot ultility
(Hot end) at Interval 3
1.670 0
245°C
I1 2.585 2.585
4.255 2.585
190°C
I2 - 2.275 - 2.275
1.980 0.310
155°C
0.033x9,4 - 0.31
I3 0
- 1.980 145.6°C
0.033x50,6
+ 1.67
- 1.67
0 0
95°C
I4 9.150 9.150
9.150 9.150
45°C
I5 1.360 1.360
10.510 10.510
35°C
I6 - 0.560 - 0.560
9.950 9.950
30°C

Emden
5 - 10
Design with two Segments above
the Process PINCH (Example 5, Variation 1)
Utility Process
PINCH PINCH
226.2°C
Hot 1 250°C 150.6°C
0.047 100°C
Hot 2 160°C 150.6°C

100°C
0.032
150°C 0.032 140.6°C 0.047
1.120 0.301 2.378

°C
185
185°C 90°C Cold 1

H
185°C 0.080 140.6°C 114.9°C 0.065 0.112
3.552 1.67 1.619
Cp in MW/K
Q in MW
H: Hot utility

Emden
5 - 11
Design with two Segments above
the Process PINCH (Example 5, Variation 2)
Utility Process
PINCH PINCH
212°C
Hot 1 250°C 150.6°C
100°C
0.047
Hot 2 160°C 150.6°C

100°C
0.032
147°C 0.047 0.047
1.786 0.301 2.378

C °
185
185°C 185°C 0.065 140.6°C 114.9°C 0.065 90°C Cold 1

H
0.112
2.886 1.67 1.619
Cp in MW/K
Q in MW
H: Hot utility

Emden
5 - 12
Simplified HEN Design Grid (Example 5)
Utility Process
PINCH PINCH
Hot 1 250°C 150.6°C 100°C

0.047
Hot 2 160°C 100°C

0.032
140.6°C 0.047
2.378
185°C 143.3°C 0.065 90°C Cold 1

H 0.112
145.2°C 119.5°C
4.672 1.67 1.92
Removal of Heat Exchanger with the load of 0.31 MW follows a

∆Tmin - Violation (150.6°C - 143.2°C = 7.4 K)
Cp in MW/K
Q in MW

Emden
5 - 13
Flowsheet of a simplified HEN with
Utility PINCH (Example 5)
50°C
2.350 MW
C Hot 2 Hot 3
100°C 160°C 100°C
2.378 MW
140.6°C
150.6°C
4.672 MW 7.280 MW
185°C 90°C 25°C
Cold 1
143.2°C
1.920 MW
145.2°C 1.670 MW
H 119.5°C
66.3°C
100°C
250°C C 1.920 MW C 5.680 MW
Hot 1
40°C 40°C
C: Cold utility
H: Hot utility
Emden
5 - 14
Energy Balance of the Heat Engine
Q1
Q2
W = Q1 - Q 2

Emden
6-1
Working Principle of a simple Heat Engine
Q1
4 1
Steam Producer
(Evaporator)
Turbine
Pump
W34 W12
Condenser
3 2
Q2

Emden
6-2
Working Steps of a
Clausius-Rankine-Steam Process
Turbine (1 2) : Isentropic expansion
Condenser (2 3) : Isobaric Condensation

(heat source)
Pump (3 4) : Isentropic compression
Evaporator (4 1) : Isobaric evaporation (heat sink)

(preheating, evaporation and
superheating)

Emden
6-3
T,s - Plot of the
Clausius-Rankine - Steam Process
K
1 Tmax
4´
4
Tmin
3 2

Emden
6-4
Integration of a Heat Engine above the PINCH
Q
Q1 Q1 = Q - W
T1
Interval 1 Interval 1
Q2 Q2
T2
Q3 Q3
Q p-1 Q p-1
Tp-1
Interval p-1 Interval p-1

PINCH Q p= 0 Q p= 0
Temperature
Interval p Interval p
Q p+1 Q p+1

Emden
6-5
Integration of a Heat Engine above the PINCH
Q1 Q1 = 0
T1
Q1
Q2 Q2 = 0
T2
Q2
W
Q3 Q3 = 0
Q p-1 Q p-1 = 0
Tp-1
Q p-1
Interval p-1 Interval p-1
PINCH Q p= 0 Q p= 0
Temperature
Interval p Interval p
Q p+1 Qp+1

Emden
6-6
Integration of a Heat Engine below the PINCH
Q1
Interval 1
Q2
Qp-1
Interval p-1
Qp = 0
PINCH
Temperature
Qp+1
Interval p
Qp+1 = 0
W
Qn - Qp+1
Interval n
Qn+1 - Qp+1 Qp+1 - W

Emden
6-7
Integration of a Heat Engine across the PINCH
Q1
Interval 1 Q
Q2
Interval p-1
W
Qp = 0
PINCH
Temperature
Q-W
Interval p
Qp+1 + (Q - W)
Interval p+1
Qp+2 + (Q - W)
Qn + (Q - W)
Interval n
Qn+1 + (Q - W)

Emden
6-8
Energy Balance of the Heat Pump
Q1
T1
T2
Q2
Q1 = Q 2 + W

Emden
6-9
Schematic of a simple Heat Pump
Q1
3 2
Condenser
Expansion Valve
Compressor
W12
Evaporator
4 1
Q2

Emden
6 - 10
Working Principle of a Heat Pump Process
Compressor : Isentropic Compression
Condenser : Isobaric Condensation

(Heat Source)
Expansion Valve : Isenthalpic Expansion
Evaporator : Isothermic Evaporation

(Heat Sink)

Emden
6 - 11
T,s - Plot of State Changes during a
Heat Pump Cycle
p2 = p 3
K
x=1
2
p1
3
x=0
1
4
h3 = h4 Q2
s3 s 4 s1 = s2 s

Emden
6 - 12
Integration of a Heat Pump above the PINCH
Q 1 -W
T1
Q+W
Interval 1
T2
Q2 +Q
W
Q p-1 +Q
Tp-1
Q
Interval p-1
Tp
Qp = 0
Interval p
Tp+1
Qp+1
Qn
Tn
Interval n
Tn+1
Qn+1

Emden
6 - 13
Integration of a Heat Pump below the PINCH
T1 Q1
Interval 1
T2
Q2
Qp-1
Tp-1
Interval p-1
Tp
Qp = 0
Q+W
Interval p
Tp+1
Qp+1 + (Q+W)
W
Qn
Tn
Q
Interval n
Tn+1
Qn+1+W

Emden
6 - 14
Integration of a Heat Pump across the PINCH
Q1 - (Q+W)
T1
Interval 1
T2
Q2
Qp-1 - (Q+W)
Tp-1
Q+W
Interval p-1
W
Tp
Qp = 0
Q
Interval p
Tp+1
Qp+1 - Q
Qn - Q
Tn
Interval n
Tn+1
Qn+1 - Q

Emden
6 - 15
Integration of Distillation Columns into a HEN
Q cond
(Tcond )
Qreb
Feed Col
Qcond
Qreb
(Treb )

Emden
6 - 16
Integration of Columns above the PINCH
T1 Q1 = Q H,min + (Q reb - Q cond )

Interval 1
T2 Q 2 + (Q reb - Q cond )
Interval 2 Q reb
T3 Q3 - Qcond Col
Interval 3 Qcond
T4 Q4
Interval 4
PINCH Q5 = 0
Tp = T5
Interval 5
T6 Q6
Interval 6
T7 Q7
Interval 7
T8 Q8 = Q C,min

Emden
6 - 17
Integration of Columns above the PINCH
Q H,min - Q cond Q reb
Col
Q cond
PINCH
Q C,min
Condenser ( Q cond ) has to be integrated.

Reboiler ( Q reb ) has not to be integrated.

Emden
6 - 18
Integration of Columns below the PINCH
T1 Q1 = Q H,min
Interval 1
T2 Q2
Interval 2
T3 Q3
Interval 3
T4 Q4
Interval 4
PINCH Q5 = 0
Tp = T5
Interval 5 Q reb
T6 Q6 - Qreb Col
Interval 6 Q cond
T7 Q 7 + (Q cond - Q reb )
Interval 7
T8 Q8 = Q C,min + (Q cond - Q reb )

Emden
6 - 19
Integration of Columns below the PINCH
Q H,min
PINCH
Q reb
Col
Q C,min - Q reb Q cond
Condenser ( Q cond ) has not to be integrated.

Reboiler ( Q reb ) has to be integrated.

Emden
6 - 20
Integration of Columns across the PINCH
T1 Q 1 = Q H,min + Q reb
Interval 1
T2 Q 2 + Q reb
Interval 2
T3 Q3 + Qreb
Interval 3
T4 Q4
Q reb
Interval 4
PINCH Q5 = 0
Tp = T5 Col
Interval 5
T6 Q6 Q cond
Interval 6
T7 Q7 + Q cond
Interval 7
T8 Q8 = Q C,min + Q cond

Emden
6 - 21
Department of
Applied Natural Sciences PINCH Method Worksheet 1
Composite curve construction rules
The composite curves of the hot and cold process streams are constructed with the
•
T, H - diagram. The required procedure has been postulated as follows:
1. Enter the temperature enthalpy profile of the hot and cold streams, which are to
be combined.
2. Generally a linear function is assumed for enthalpy-temperature relationship.

The heat capacity flow rates are calculated according to:
•
•
∆H
Cp =
∆T
Corresponding to the above algorithm, the heat capacity flow rate is constant
within all temperature intervals.
3. The beginning and end temperatures of all individual hot and cold streams
indicate the temperature range within each temperature interval of the plot.
These intervals are highlighted by dotted lines.
4. The next step consists of the addition of the individual hot heat capacity flow
rates within each temperature interval.
5. Simultaneously the same is done for all cold heat capacity flow rates within
each interval.
• •
6. For each temperature interval a T, H - curve results. The slope of the T, H -
interval is determined by the sum of individual heat capacity flow rates occurring
in each interval. The slope algorithm is postulated as follows:
∆T 1
tan α = •
= •
∆H i ∑ Cpi
•
7. The complete hot composite curve is set together by joining the individual T, H -
curves.
8. The cold composite curve can be completed in the same way.
9. The hot and cold composite curve show how the individual streams would
behave if they were a single stream.
worksheet_1_03-04-02.doc
Department of
HEN design grid
The network design grid can be produced by the following procedure:
1. The hot and cold streams are numbered separately. The use of the declarations
cold and hot for the numbering is recommended.
2. All individual cold streams are marked by horizontal lines running from right to
left on the schematic. The inlet and outlet temperature values should be entered
at each end of the streams.
3. Simultaneously all individual hot streams are marked by horizontal lines running
from left to right on the schematic.
4. A heat exchanger always indicates the coupling of two streams (hot and cold).
The couplings should be marked by circles, which connect a hot with a cold
stream. The heat duty of the exchanger should be entered on the schematic
too.
5. Coolers and heaters are shown by circles with the corresponding heat duty.
6. Intermediate temperatures should be entered at each temperature change.
7. It is always helpful to enter all enthalpy differences and heat capacity flow rates
within the HEN design grid.
•
C p - table
•
C p tables are produced separately for the process streams below and above the
PINCH. They each consist of two columns.
•
1. Arrange the hot streams with decreasing C p - value in the left column.
•
2. Arrange the cold streams with decreasing C p - value in the right column.
•
It is helpful to designate the C p table with the corresponding stream type.
Department of
HEN design rules
Rule 1: Split the process into two independent subsystems at the PINCH.
Rule 2: Design the HEN above and below the PINCH independently.
Rule 3: Above the PINCH the use of cold utility must be avoided, and no hot utility
can be placed below the PINCH.
Rule 4: The designer should start at the PINCH, because the PINCH is the most
constrained part of the problem.
Rule 5: The design must be checked against the arguments and criteria, which
were postulated before. Using the stream-splitting concept is a good tool
to simplify the design.
Rule 6: The streams which are to be combined, must be coupled in the order with
decreasing heat capacity flow rates, because these can best be matched
at the beginning of the design.
Rule 7: The heat duty of each exchanger must be chosen to be as large as

possible.
Rule 8: Bringing a stream to PINCH temperature, the stream which is to be

coupled should have a similar heat capacity flow rate and should start at
the PINCH within the subsystem. If a stream must be split, the splitting
must to be done according to the principle explained in section 4. If this
rule is satisfied, then both streams are used optimally and do not need to
be further considered in the design (tick-off-heuristic).
Rule 9: Avoid mixing streams with different temperatures.
Rule 10: The placement of coolers and heaters should be done as the final step in
the design. Note that the heat duties of the cold and hot utilities must
conform to the values from the energy analysis (heat cascade or graphical
setting).
Department of
Applied Natural Sciences PINCH Method Worksheet 4/1
Calculating the heat cascade
The table algorithm for the cascade can be used to calculate energy targets. The
calculation can be done in four steps (use worksheet 5).
step 1:
1. Increase the temperature of cold streams by ∆Tmin/2.
2. Decrease the temperature of hot streams by ∆Tmin/2.
3. Enter the streams into the worksheet.
4. Determine the temperature intervals and enter them into the corresponding
column.
step 2:
The second step includes the energy balancing for each interval. The heat capacity
flow rates of hot streams count negative and those of cold streams count positive.
1. Sum up the heat capacity flow rates for each interval.
• •
2. Determine the enthalpy flow rates ∆ H i by multiplying the C pi with the
temperature difference ∆Ti.
3. Positive values for enthalpy flow rates indicate a deficit and negative values a
surplus.
step 3:
The heat duty in each interval is solved by removing or adding heat from external
heat sinks or sources (see column “Balanced Energy ...”). The heat balance allows
maximum heat recovery within each interval. However, heat recovery can also be to
carry out between intervals.
The surplus heat can now be cascaded down the temperature scale from interval to
interval. The point where the heat flow approaches the minimum corresponds to the
PINCH.
Department of
Applied Natural Sciences PINCH Method Worksheet 4/2
step 4:
The cascade is solved by adding the amount of heat with which the energy flow
becomes zero at the PINCH to the hot utility at the top of the cascade. This does not
change the heat balance of the heat cascade but increases all the heat flows
between the intervals. This permisses an energy flow from high temperatures to low
temperatures.
The energy flow can now be cascaded down the intervals till the energy goes to zero
at the PINCH (column “cascade 2”). At the top of the cascade the smallest amount of
heat can be seen which must be added to the hot utility. The amount of heat to be
removed shows the value at the bottom of the cascade. The results correspond with
the graphical setting of the composite curves. Finally the heat cascade concludes
with “cascade 3” in which the enthalpy differences are shown as surpluses and
deficits.
Worksheet 5: Heat Cascade
( Please Note: Hot and cold streams must be shifted by ∆Tmin /2. Hot streams: - ∆Tmin /2. Cold streams: + ∆Tmin /2. )
Balanced energy
number
Σ Cp i
Interval
Hi
Surplus
Deficit /
Streams within the interval
Cascade 1 Cascade 2 Cascade 3
[K] [ kW/K ] [ kW ] Hi
T1 = °C
1
T2 = °C
2
T3 = °C
3
T4 = °C
4
T5 = °C
5
T6 = °C
6
T7 = °C
Q H, min = kW Q C, min = kW TPINCH = °C TPINCH, H = °C TPINCH, C = °C

Energy Saving by Optimal Energy Recovery (PINCH)

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Energy Saving by Optimal Energy Recovery (PINCH)

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Energy Saving

Optimal Energy Recovery

Prof. Dr.-Ing. Gerhard Kleemann

1. Problem Definition and Solving Strategy 2

1. Problem Definition and Solving Strategy

to a certain temperature (feed-in products of distillation columns or vessels, boiler

To solve the recovery problem

1. Increase of the exchanged energy flow in the IS.

Therefore it’s necessary to develop and solve a complex

If the target is formulated as a function of capital and energy costs, different

1.2. The Solution

To solve the problem it is helpful to divide it into two parts:

Design of the heat exchanger network:

• Definition of the main dimensions of the heat exchangers

• Preliminary determination of the parameters of the streams such as heat

Design and scaling of the heat exchanger network:

• Design of all necessary heat exchangers including the exchangers in the

The first stage: Energy analysis of the recovery problem.

The second stage: Structural design of the heat exchanger network.

2. The Energy Analysis

The energy analysis can be done by two equivalent methods:

1. Graphical method: Design of the composite curve.

For both methods the following parameters are assumed to be known:

2.1. Designing the Hot and Cold Composite Curves

The graphical method consists of designing a

temperature - enthalpy diagram,

which shows all individual cold and hot streams in a single

hot and cold composite curve

2.2. Determining the Heat Recovery PINCH

To determine the PINCH point two working steps are introduced:

1. Targeting the minimum temperature difference ? Tmin

heat recovery PINCH or process PINCH.

At the PINCH three temperatures can be seen:

• PINCH temperature of the hot composite curve (TPINCH,H)

• PINCH temperature of the cold composite curve (TPINCH,C)

• PINCH temperature TPINCH

2.3. Conclusion of the Composite Curve Diagram

Subsystem above the PINCH (in temperature terms):

Subsystem below the PINCH (in temperature terms):

The results of example 1 are illustrated in Fig. 2-4.

are represented by Fig. 2-5 and 2-6.

2.4. The Heat Cascade

The hot composite curve is shifted by –? Tmin/2 under constant enthalpy

The cold composite curve is shifted by +? Tmin/2 under constant enthalpy

This basic approach can be developed into a formal algorithm known as

2.5. The Utility PINCH

The necessity for this diagram will be discussed later.

3. Designing the Heat Exchanger Network (HEN)

3.1. Rules for Designing a HEN

• Network design grid

3.2. Criteria for the Design at the PINCH

Guidelines above the PINCH:

Cooling above the PINCH is an inappropriate use of utilities.

Guidelines below the PINCH:

3.3. Example for the Design of a HEN

Problem Fig. 3-8

Heat cascade Fig. 3-9

Cp-table Fig. 3-10

HEN design grid Fig. 3-11

HEN flowsheet Fig. 3-12

Problem Fig. 3-13

Heat cascade Fig. 3-14

Cp-table Fig. 3-15