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PROCESS INTEGRATION THROUGH PINCH ANALYSIS

Article · June 2012

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 PROCESS INTEGRATION THROUGH PINCH
ANALYSIS
1
MR. J.J. MAKADIA, 2 MR.V.H.MODI, 3 DR. C.D.SANKHAVARA
1
M.E.[Thermal Science] Student, Department Of Mechanical Engineering, R.K. College
Of Engineering And Technology, Rajkot, Gujarat
2
M.E.[Thermal Science] student, Department Of Mechanical Engineering R.K. College
Of Engineering And Technology, Rajkot, Gujarat
3
Principal, R.K.College of Engineering And Technology, Rajkot, Gujarat
Jiten_mona@yahoo.com, vikrammodi02@yahoo.co.in, cdsankhavara@yahoo.co.uk

ABSTRACT:
Process-integration techniques based on pinch technology represent a new and powerful way to optimize
process designs, yielding results superior to those achievable using conventional methods. These new
techniques permit the design engineer to track the energy flows in a manufacturing process more clearly and to
modify the process to reduce energy consumption. Pinch technology also enables the design of an optimum
interface between the process and the utility systems. Pinch analysis has been widely accepted in process plants
in developed countries resulting in significant energy saving. Present article highlights an overview of Pinch
technology for process integration and its application in thermal power plants.

Keywords—Pinch Analysis, Composite Curves, Process Integration, Power plant, HEN(Heat exchanger
network)

Introduction: Process Industries [5,6,7,8,9]. During last years,

According to lack of energy sources and increasing
number of consumers, a need to present samples of
optimization is felt. In industrial experiences, the
calculation of the minimum heating and cooling
requirements reveal significant energy savings.
Process integration, especially pinch technology is a
powerful analytical method for identifying and
selecting concrete technical solution to improve
efficiencies and provide an optimum manufacturing
solution. The first step in the energy integration
analysis is the calculation of the minimum heating
and cooling requirements for heat exchanger network
(HEN). A heat exchanger, exchanges heat between a
hot and a cold process stream: the hot stream needs to
be cooled and the cold stream needs to be heated. In
steam power plants, it can be observed from cycle
thermodynamics that synthesis of an optimal HEN
with minimization of utilities, may improve cycle
efficiency. So the design of relating HEN for
optimum efficiency is a main aim of using pinch
technology in a power plant optimization.
Thermodynamic approaches in the form of Pinch
Analysis have been first introduced in the late 1970s
with the idea of setting targets prior to design and
were originally developed at the ETH Zurich and
Leeds University (Linnhoff and Flower 1978 [1,2];
Linnhoff 1979[3]). ICI plc took note of these
promising techniques and set up research and
application teams to explore and develop them [4].
Pinch analysis reports significant changes in energy
savings and has established a track record of
numerous successful applications in the Chemical
pinch technology has been developed in other area of
process industries, including power plants and
showed satisfactory results, respect to energy saving.
Linn Hoff and Alanis have done much research work
on the using of pinch technology in various power
plants. Their research model was based on modifying
of an existed site [10]. Combined pinch and exergy
analysis, as a second model, was introduced by Dhole
and Zheng [11]. This model could use from exergy
concept instead of pure thermal analysis with aid of
pinch technology ability in design and targeting. In
the last decades, extensive efforts have been made in
the fields of energy efficiency improvement and
energy recovery technologies.
The Concept of Pinch Analysis:
Pinch analysis is a new thermodynamic concept
where a proper analysis of Process Heat Exchange is
done. Appropriate Thermodynamic analysis also
leads to identification of preferred options in terms of
many other design objectives, for example,
minimization of capital cost and operational cost.
In Chemical Process, the engineering design
problems are dealt in two ways.
-- Unit Operation level or
-- Total system design level
In Pinch Analysis, the system design problems are
considered for identification of Energy saving
opportunities and modification of existing plant or
for designing of a new energy efficient plant. The
approach vests on concepts that are convenient and
simple and make it possible to deal with problems
hither to considered complex. The technique
emphasizes on simple sums rather than complex
mathematics.
Process Heat Exchange Analysis:
The hot and cold streams in a process are identified
and represented on a Temperature – Enthalpy graph.
The analysis work is started from the individual
streams and by simple summing of heat contents over
temperature ranges, composite curves of all hot
streams and cold streams in a process are constructed.
The results of hot and cold streams of two composite
curves are plotted in a single curve and overlap
between the composite curves represents the
maximum amount of heat recovery possible with in
the process. (Fig. 1). The hot “overshoot” of the hot
composite curve represents the minimum amount of
external cooling required. Similarly the “overshoot”
of the cold composite curve represents the minimum
amount of external heating. Both curves approach
closely at one point, which is known as “Pinch” (Fig.
1). Pinch is a point below which the system
represents itself as a heat source i.e. heat goes out to
the cold utilities but no heat goes in. Above Pinch the
system is a heat sink. Heat goes in from the hot utility,
no heat goes out. The system is therefore separated at
the Pinch in total hot and cold requirements of the
processes and indicates the amount of excess heating
or cooling being done within the system. In a system
where only required heating and cooling are
maintained, the heat flows across the Pinch is zero.
This system is identified as a system where utility
targets are achieved very close to optimal conditions
(Fig. 3a). In a system where external heating is done
in excess over the minimum possible requirement of
the processes. The heat balance shows a heat flow
across the Pinch, therefore an excess external cooling
is required (Fig. 3b).
Energy Targets:
The technique provides a way to set energy targets
for optimizing the heat recovery systems. The T-H
diagrams (Fig- 4) are made for hot and cold utilities
which represent thermal characteristic of process
streams. For example for a stream requiring heating
(cold stream), the temperature is raised from “Supply
temperature” (TS) to a “Target temperature” (T T). The
total heat added (Q) will be equal to the Stream
enthalpy change (ΔH).
Tt
Q= ∫ Cp dT = Cp (Tt - Ts) = ∆H
Ts
Cp = Heat capacity flow rate (KW/K)
= Mass flow rate (kg/s) x Specific heat (Cp)
dT = Differential temperature change
Composite Curves:
Heat exchange between many hot and many cold
streams can be analysed similarly. A single
composite of all hot and a single composite of all
cold streams can be produced in the T-H diagram,
and handled in just the same way as the two-stream
problem. (Fig. 5) shows a typical pair of composite
curves. Shifting of the curves leads to behaviour
similar to that shown by the two stream problem.
Now though, the “kinked” nature of the composites
means that ΔTmin can occur anywhere in the
interchange region and not just at one end. For a
given value of ΔTmin the utilities quantities predicted
are the minima required to solve the heat recovery
problem. Note that although there are many streams
in the problem, in general ΔTmin occurs at only one
point, termed the “pinch”. This means that it is
possible to design a network which uses the
minimum utility requirements, where only the heat
exchangers at the pinch need to operate at ΔT values
down to ΔTmin.
Application of Pinch Concept in Thermal Power
Plant:
Pinch analysis has been found useful in thermal
power generation industry for setting energy targets
and optimizing the heat recovery systems. Using this
methodology in a steam power plant, successful cost
effective process integration and design approaches
have been adopted to maximize the heat recovery.
In order to plan the main diagram in the pinch
analysis, the cold and hot streams in the cycle must
be specified, and subsequently the related
information is obtained by using thermodynamic
characteristics in the various parts of the cycle. In a
steam turbine power plant, drain streams from
turbine, which are used for feed water preheating,
also outlet steam from the last part of the low
pressure turbine, are supposed as power plant hot
streams
In a typical case (fig.2), the below streams
classification is done as hot and cold streams (table 1).
All process heating and cooling duties are reviewed;
Stream data is then extracted as hot and cold streams
according to analysis procedure to derive composite
and grand composite curves. Pinch technology
provides a methodology to confidently select the
most appropriate projects for a given set of
circumstances.
 Pinch analysis can also be used to optimize
the steam extraction levels from the
turbines.
 Pinch principles can be used for
cogeneration schemes consideration by
appropriately integrating the pass out steam
for heating to the processes by selecting the
pass out pressures.
  The composite curves can also be used to
determine the boilers minimum fuel
requirements.
 plants can be designed as network based on
the flow sheet and propose the modifications
easily by using composite curves.
 The plants can also easily evaluate the
energy demand and benefits in retrofits as
well as new design. For a given pay back
criterion, it enables the appropriate level of
investment to be determined and the
corresponding energy savings to be
identified before the design is begun.
 Integration, Elsevier, 2007.
 Pinch technology can be helpful to design
integrated plants for a wide range of
operating conditions, such as seasonal
variations, changes in raw material or
product specifications etc. It can help to
achieve good flexibility in the design at a
lower cost than can be achieved using
traditional design methods.
Process integration by Pinch analysis is good for
identifying fundamental insight into heat transfer and
mass transfer problems and also help the industry to
set target for its reduced energy and water
consumption. Other benefits include correct
integration of steam turbines, co-optimisation of
energy and capital cost by super targeting,
identification of most appropriate process changes
and increased plant flexibility.
Conclusion:
Pinch Technology is known as a powerful tool in
designing and optimization of processing systems.
This technology is used in power plant industries and
causes appropriate application of temperature
differences in the HENs and the cycle modification.
using of this technology makes an increase of total
efficiency as well as decrease of the use of fuel. In
this way, the thermal load is reduced for the steam
production. On the other hand, decrease of the fuel
causes using of smaller furnace and saving in cost of
power plant. Finally less fuel consumption leads to
decrease in pollution.
References:
[1]. B. Linnhoff, J. R. Flower, “Synthesis of heat
exchanger networks. Part I: Systematic generation of
energy optimal networks”, AICHE J., vol. 24, no. 4,
1978, pp. 633-642.
[2]. B.Linnhoff, J. R. Flower, “Synthesis of heat
exchanger networks. Part II: Evolutionary generation
of networks with various criteria of optimality”,
AICHE J., vol. 24, no. 4, 1978,
pp. 642-654.
[3]. B. Linnhoff, Thermodynamic analysis in the
design of process networks, PhD Thesis, University
of Leeds, 1979.
[4]. I.C. Kemp, Pinch Analysis and Process
[5]. T., Umeda, T.Harada, K., Shiroko, “A
thermodynamic approach to the synthesis of heat
integration systems in chemical processes”, Comp.
Chem. Engg., vol. 3, 1979, pp. 273- 282.
[6]. S. Ahmad, Heat Exchanger Networks: Cost
tradeoffs in energy and capital, PhD Thesis,
University of Manchester, Institute of Science and
Technology, 1985.
[7]. B. Linnhoff, E. Hindmarsh, “The pinch design
method of heat exchanger networks”, Chem. Eng.
Sci., vol. 38, no. 5, 1983, pp. 745-763.
[8]. B. Linnhoff, G.T, V.Polley, Sahdev, “General
process improvement through pinch technology”,
Chem. Eng. Prog., June 1998, pp. 51-58.
[9]. L. Tantimuratha, A.C. Kokossis, F.U. Müller,
“The heat exchanger network design as a paradigm of
technology integration”, Applied Thermal
Engineering, vol. 20, 2000, pp. 1589-1605.
[10]. B. Linnhoff, F.J. Alanis, “Integration of a new
process into an existing site: A case study in the
application of pinch technology”, Journal of
Engineering for Gas turbine and power, vol. 113,
1991, pp. 159-169.
[11]. V.R. Dhole, J.P. Zheng, “Applying combined
pinch and exergy analysis to closed cycle gas turbine
system design”, Journal of Engineering for Gas
turbine and power, vol. 117, 1995,
pp. 47-52.
[12] Uday V. Shenoy, “Heat exchanger network
Synthesis”,gulf professionl publication, ,ISBN:
0884153916.
Annexure: Figures and Tables

Figure 1

Figure 2

Heat content (H), KW

Figure 3a
Figure 3b

Figure 4

Figure 5
 STREAM PARTICULAR: TYPE:
Feed pump outlet – feed water heater 1 outlet Cold
Feed water heater 1 outlet – feed water heater 2 outlet Cold
Feed water heater 2 outlet – feed water heater 3 outlet Cold
Feed water heater 3 outlet – deaerator outlet Cold
Deaerator outlet – feed water heater 5 outlet Cold
Feed water heater 5 outlet – feed water heater 6 outlet Cold
Boiler inlet – boiler outlet Cold (utility)
Reheater inlet – reheater outlet Cold
Drain stream 1 Hot
Drain stream 2 Hot
Drain stream 3 Hot
Drain stream 4 Hot
Drain stream 5 Hot
Drain stream 6 Hot
Condenser inlet – condenser outlet Hot (utility)
Gland steam Hot
Ejector steam Hot

Table 1

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