Introduction To Pinch Technology

Introduction to Pinch Technology

Topics
Introduction
Heating Curves
Composite Curves
Pinch Point
Network Design
Crude Distillation Check
Quiz

Introduction
Representation of exchangers and streams
H1
H2
H3
Cold
C1
C2
Hot
This diagram suitable
for two streams.
C3
For many streams, this diagram
provides a schematic.

Introduction
Exercise
- Two Hot Streams
- Two Cold Streams
- Steam and Cooling Water
- Temperatures and Duties from Table
Stream
H1
H2
C1
C2
Steam
CW
WCp
0.05
0.20
0.075
0.125
Tin Tout
315 240
240 140
40 130
130 260
350 350
27 40
Q
-3.75
-20.0
+6.75
+16.25
W = Mass
Cp = Heat Capacity
CW = Cooling Water
Q = Duty

Introduction
Exercise
For the given Basis, calculate the following:
- How many exchangers are required?
- What size are the exchangers?
- How much steam and cooling water are required?

Introduction
Exercise
Provide a solution using the Dumbbell representation
350
350
Steam Steam Load
130
260
40
130
315
240
240
140
40
27
= 23 Units
C1
C2
H1
H2
CW
What is downside of this scheme?

Formulate another exchanger network.
CW Load
= 23.75 Units

Introduction
Exercise
Provide an alternate network solution reducing utility load
350
350
Steam
130
40
WCp=0.075
WCp=0.125
260
130
WCp=0.050
315
240
WCp=0.200
240
140
40
27
C1
C2
H1
H2
CW
Heat Exchanger
Calculate stream temperatures and duties.......

Introduction
Exercise
350
350
Steam
130
40
WCp=0.075
WCp=0.125
260
WCp=0.050
315
WCp=0.200
240
130
xxx
240
C1
Duty=xxx
C2
H1
Duty=xxx
140
xxx
H2
40
27
CW
Heat Exchanger
Duty=xxx
Duty=xxx

Introduction
Exercise
350
350
Steam
130
40
WCp=0.075
WCp=0.125
260
WCp=0.050
315
WCp=0.200
240
130
160
240
C1
Duty=6.75
C2
H1
Duty=3.75
140
206
H2
40
27
CW
Heat Exchanger
Duty=12.50
Duty=13.25

Introduction
Questions
- Will both exchange networks work?
- Which is better?
- Is there a better network?
- How many combinations of exchange are there?
Conclusions
- Is there a need for an early systematic approach
to exchanger network design?
- The answer to a systematic approach is called
PINCH TECHNOLOGY. It will benefit the
process engineer by providing:
Better planning
Targets for the Utilities
Estimate exchanger targets early
Optimized designs

Introduction
Process Integration
Power
Energy
Recovery
Feed
Heat Reaction
Feed
Products
PROCESS UNIT OR
COMPLEX
Cold
Utility
Products
Products
Hot
Utility
Once the basis of design is established, the Process Engineer

must do the engineering to define the structure within the box.
PINCH TECHNOLOGY is one of the modern tools available
for the Process Engineer.

Heating Curves
Construction of Heating Curves
- Two Fluids with constant Cp
- Two Fluids with changing Cp
- Two Fluids with hot and cold utilities
- Finding optimum approach of hot and cold curves

Heating Curves
Two Fluids with constant Cp
600
Temperature
500
Hot
400
300
Cold
200
100
0
0
0.2
0.4
0.6
0.8
Fraction of Thermal Duty
1.0

Heating Curves
Two Fluids with changing Cp
600
Temperature
500
400
Hot
300
Cold
200
100
0
0
0.2
0.4
0.6
0.8
Fraction of Thermal Duty
1.0

Heating Curves
Two fluids with hot and cold utilities
600
What is Hot Utility?
Temperature
500
400
300
What is Cold Utility?

Hot
Cold
What is Exchanger
Duty?
200
What is Minimum
Temperature Approach?
100
0
0
20
40
60
80
Thermal Duty, MMBTU/Hr
100

Heating Curves
Two fluids with hot and cold utilities with infinite exchange
600
What is minimum
heating utility?
Temperature
500
400
300
Hot
What is minimum
cooling utility?
Cold
200
What is temperature
approach?
100
0
0
20
40
60
80
Thermal Duty, MMBTU/Hr
100
Is this a reasonable
design?

Heating Curves
Find the optimum approach:
Tabulate Utility, Capital & Total Cost vs Approach
1200
1000
800
Utility
600
Capital
Total
400
200
0
0
20
40
60
80
100
Delta T Minimum (approach)

Heating Curves
Conclusions
- Two Fluid System
Understandable
Simple
Minimum Calculations
- Extend to PINCH TECHNOLOGY
Many Streams
Overlapping Temperature Ranges
Many Utilities (Steam, CW, Air, Fuel Oil & Gas)
Algorithms for Matching Exchangers
Composite Curves
Plot all cooling services as a single composite curve
Hot
Composite
Plot all heating services as a single composite curve
Cold
Composite
T
Q

Composite Curves
Plot the hot composite streams on a Crude Distillation Unit
STREAMS
TEMPERATURE, DEG F
IN
OUT
Reduced Crude
Gas Oil PA
Diesel PA
Gas Oil Net
Diesel Net
Kerosene Net
Overhead Vapor
Assumptions:
Step One:
Step Two:
Step Three:
Step Three:
Step Four:
665
590
530
570
510
400
285
175
440
380
120
120
100
140
DUTY, Q
MMBTU/HR
167.6
40.0
60.0
27.0
22.5
29.1
186.7
Specific Heat constant from inlet to outlet temperature.

Line up intervals from lowest to highest.
100, 120, 140, 175, 285, 380, 400, 440, 510, 530, 570, 590, 665
Determine which intervals are common to which streams.
Determine the mean specific heat for each stream.
Determine duty associated with each interval.
Plot the temperature vs. duty composite curve.

Composite Curves
100 120 140 175 285 380 400 440 510 530 570 590
(WxCp) 120 140 175 285 380 400 440 510 530 570 590 665
Reduced Crude
Gas Oil PA
Diesel PA
Gas Oil Net
Diesel Net
Kerosene Net
Overhead Vapor
Total
Cumulative
0.342
0.267
0.400
0.060
0.058
0.097
1.288
38 32
1
1
2
2
2
4
6
2
2
4
45
14
8
7
6 1
7
6 1
11 10 2
142
16
2
2
24
19
28
4
4
7
5
8
1
14
11
7 26
5
53 205 54 19 34 79 21 27 12 26
59 264 318 337 371 450 471 498 510 536
Temperature, Deg F
Composite Curves
Hot Composite Curve
800
700
600
500
400
300
200
100
0
0
100 200 300 400 500 600 700 800 900

Duty, MMBTU/HR

Composite Curves
Practical use of composite curves
Minimum Delta T or Pinch
600
Hot
Composite
Temperature
500
400
300
Cold
Composite
200
100
0
0
20
40
60
Thermal Duty
80
100
120

Composite Curves
Hot Utility Target
600
Hot
Composite
Temperature
500
400
300
Cold
Composite
200
100
0
0
20
40
60
Thermal Duty
80
100
120

Composite Curves
Cold Utility Target
600
Hot
Composite
Temperature
500
400
300
Cold
Composite
200
100
0
0
20
40
60
Thermal Duty
80
100
120

Composite Curves
Exchange between Hot and Cold Streams
600
Hot
Composite
Temperature
500
400
300
Cold
Composite
200
100
0
0
20
40
60
Thermal Duty
80
100
120

Composite Curves
The cold composite can be drawn at any location along the
Q axis as long as T and slopes are maintained. What changes?
600
Hot
Composite
Temperature
500
400
300
200
100
0
0
20
40
60
Thermal Duty
80
100
120
140

Composite Curves
The cold composite can be drawn at any location along the
Q axis as long as T and slopes are maintained. What changes?
600
Hot
Composite
Temperature
500
400
300
200
100
0
0
20
40
60
80
100
120
140
Thermal Duty
Note:The change in the Pinch value is proportional to the change in total utility load.

Pinch Point
Find the optimum Delta T Minimum
Tabulate Utility, Capital & Total Cost vs Delta T Minimum
1200
1000
800
Utility
600
Capital
Total
400
200
0
0
20
40
60
80
Delta T Minimum
Pinch Point
100

Pinch Point
Once pinch is set, optimum exchange layout must take
advantage of maximum temperature driving force.
600
Hot
Composite
Temperature
500
400
300
Cold
Composite
200
100
0
0
20
40
60
Thermal Duty
80
100
120

Pinch Point
Rules to maximize thermal driving force at desired PINCH POINT
Maintain vertical driving force with exchanger selections

Select matches with exchangers 100% above pinch
Select matches with exchangers 100% below pinch
Do not use cooling utility above pinch
Do not use heating utility below pinch

Pinch Point
Rules of Thumb for various processes
- Refrigeration
10 deg F Pinch
- Petrochemical
30 deg F Pinch
- Petroleum
50 deg F Pinch
- High Pressure Units 100 deg F Pinch
Remember once the Pinch is set
- Hot Utility is fixed
- Cold Utility is fixed
Remember exchanger constraints
- Some exchanger configurations are undesirable
- Constraints may prevent attaining desired Pinch

Network Design
Summary:
- Generate composite curves
Stream data
Temperature data
- Select optimum Pinch Point
Capital costs
Utility costs
- Rules for exchanger selection
No heat transfer across the Pinch Point
Start at Pinch Point and work outward(above & below)
Maintain maximum temperature driving force
Never let exchanger approach drop below Pinch Point

Network Design
Software
- Is there software to help the Process Engineer?
Linhoff March
Advent
Hysim/Sim Sci
Spreadsheets
- Can software make the exchanger matches?
Yes, as good as the algorithms
Do not underestimate the human interface
- Let us go through with an example

Network Design
Example
Start the grid by showing all the hot streams(requiring
cooling) to go from left to right and the cold streams
(requiring heating) to go from right to left.
Stream Type
Cold
Hot
Cold
Hot
W x Cp TempIn
2.0
3.0
4.0
1.5
TempOut
20
170
80
150
135
60
140
30
Plot the composites with a Pinch Point of 10 degrees.

Network Design
Temperature
Example
180
160
140
120
100
80
60
40
20
0
Heating Utility = 20
Cooling Utility = 60
Pinch
= 10
200
Thermal Duty
400
600

Network Design
Example
Layout streams in a grid with the center line at the
Pinch temperatures.
W x Cp Duty
above below
(2)
170
90
90
60
3.0
240 90
(4)
150
90
90
30
1.5
90
135
80
80
20
2.0
110 120
140
80
4.0
240
(1)
(3)
90

Network Design
Example
Start matching exchanger above the Pinch
(2)
170
90
(4)
150
90
135
80
(1)
(3)
140
80
170 - 90
140 - 80
30 10
Q = 240
Hot Utility
125 - 135
Q = 20
150 - 90
125 - 80
25 10
Q = 90
W x Cp
Duty
above
3.0
240
1.5
90
2.0
110
4.0
240

Network Design
Example
Match exchangers below the Pinch
(2)
(4)
(1)
(3)
90 - 60
80 - 35
10 25
Q = 90
90 - 70
35 - 20
55 50
Q = 30
Cooling Utility
70 - 30
Q = 60
W x Cp
Duty
below
90
60
3.0
90
90
30
1.5
90
80
20
2.0
120

Crude Distillation Unit Design Check
The hot composite streams for the Crude Distillation Unit have
been plotted. Now plot the cold composite streams. Use the exiting
heater duty as the hot utility. What is the resultant Pinch Point?
STREAMS
IN
OUT
TEMPERATURE, DEG F
Crude to Desalter
Crude to Heater
Crude to Flash Zone
Debut Reboiler
60
250
449
374
260
449
705
375
MMBTU/HR
DUTY, Q
126.2
152.7
273.7
20.0

705 449 375 374 260 250
(WxCp) 449 375 374 260 250 60
Crude to Fl Zone
Crude to Heater
Crude to Desalter
Debut Reboiler
1.069
0.767
0.631
20.0
274
57
Total
274 57
Cumulative (536+274 = 810) 536 479
87
8
6
120
20
21 87 14 120
458 371 357 237
Temperature, Deg F

Hot Composite Curve
800
700
600
500
400
300
200
100
0
0
100 200 300 400 500 600 700 800 900

Duty, MMBTU/HR
Temperature, Deg F

Composite Curves
800
700
600
500
400
300
200
100
0
0
100 200 300 400 500 600 700 800 900

Duty, MMBTU/HR

Quiz
1. Based on the individual streams below, calculate the heat duty for the hot
composite curve in the 180-150 deg range.
Stream Q, MMBTU/H
Tin
Tout
1
20.0
200
100
2
4.5
180
150
3
12.0
160
130
a. 4.5 MMBTU/H
b. 22.5 MMBTU/H
c. 14.5 MMBTU/H
2. The complete composite curve for the streams in Problem 1 would consist
of how many separate temperature zones?
a. 5
b. 3
c. 1
3. The Pinch Point is determined as:
a. The point where the heating and cooling curve cross
b. The temperature difference between the two composite curves that
results in the optimum economic cost.
c. The point where the composite curves just touch

Quiz
4. The physical significance of the reducing the Delta Tmin is to:
a. Increase the heat exchange surface area
b. Reduce capital cost
c. Decrease the heat exchange surface area
5. When designing an oil processing facility, a recommended target
pinch temperature is:
a. 70 deg F
b. 50 deg F
c. 20 deg F
6. When selecting the streams that should be used to exchange heat, which
rule of network design applies?
a. Do not exchange heat across the Pinch Point
b. Minimize vertical temperature driving force
c. Exchanger temperature differentials less than the pinch point
temperature are acceptable
7. Heating and cooling utilities are fixed when the pinch point temperature
is selected.
a. True
b. False

Quiz
8. From the composite curves developed for the crude unit design, what
is the value of the pinch point temperature?
a. 200 deg F
b. 136 deg F
c. 155 deg F
9. If the cold composite curve developed for the crude unit design is repositioned
laterally to the left, what happens to the heating utility.
a. Increases
b. No change
c. Decreases
10. Pinch technology can be used to help and aid with the process flow scheme
selection.
a. True
b. False

Introduction To Pinch Technology

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