Process Equipment Design-I

Assignment II

Group 3

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USING PINCH ANALYSIS TO
OPTIMIZE THE HEAT
EXCHANGER NETWORK

Submitted to:
Prof G. Das
Asst. Prof S. Ray

Submitted by:

Sourav Kundu
Souvik Paul
Sanket Verulkar
Subhrajit Chowdhury

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 PART-I
TABLE OF CONTENTS

Problem Statement 4

Basic Theory 5

Heat exchanger data for the flowsheet 8

Calculations for = 10 8

Calculations for = 20 13

Heat exchanger network for = 10 17

Design 1 feasible 18

Design 2 infeasible 19

Design 3 infeasible 20

Design 4 infeasible 21

Discussion on feasible design 22

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Problem Statement
i. Draw the composite curves and problem table cascades for = 10 =
20. Tabulate the targets for hot and cold utility in each case.
ii. Calculate the area target assuming the steam at 250C condenses to 249C as hot utility and
cooling water at 20C get heated to 25C by serving as cold utility.
iii. Calculate annualised cost and optimum for the process.

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Basic Theory:
Definitions
Pinch Point The location of the smallest difference between hot and cold streams in a
heat transfer network.
Supply Temperature The temperature at the inlet of a heat exchanger.
Target Temperature The temperature goal at the outlet of the heat exchanger.
Stream Fluid that must be heated or cooled.
Heat Capacity Flowrate Mass flowrate multiplied by the enthalpy of the fluid for the given
temperature range.
Heat Load The maximum amount of heat that could be transferred to or from a
stream.
Composite Curve Graph of temperature versus enthalpy for the cold and hot stream data.
Grand Composite Curve Graph of the combination of the hot and cold composite curves, used to
determine external utility requirements.
Utility An external source of heating or cooling that does not use
energy from the streams in the system.

Acronyms
GCC Grand Composite Curve
SCC Shifted Composite Curve
HEN Heat Exchanger Network
SG Stream Generator
LP Low Pressure
HP High Pressure

Pinch Analysis
Optimizing the thermal efficiency and overall cost of a power plant can be determined by pinch analysis.
Linnhoff & Flower developed pinch analysis, at the ETH Zurich & Leeds University, in 1978. Pinch analysis
is a means of optimizing a power plant by using the heat energy from the streams, instead of using
external heating and cooling methods (heat exchanger, furnace, cooler, etc.), to increase the thermal
efficiency of the plant and minimize energy costs. Streams are any flow paths that do not change in
chemical composition. Pinch analysis can be used for designing new, or retrofitting existing, power plants.
Pinch analysis utilizes energy targets, which are absolute thermodynamic targets, showing what the
process is inherently capable of achieving if the heat recovery, heating and cooling systems are correctly
designed. The principle is to predict what should be achieved (targeting), and to then set out to achieve
it (design).

Second Law of Thermodynamics

Pinch analysis is based on the second law of thermodynamics. The second law of thermodynamics
describes the spontaneous processes that exist in irreversible (non-ideal) cycles. The Clausius Statement
of the second law of thermodynamics states: it is impossible for any system to operate in such a way
that the sole result would be an energy transfer by heat from a cooler to a hotter body. A hot stream
cannot be used to heat a cold stream to a temperature hotter than the hot stream. The Kelvin-Planck
Statement of the second law states: it is impossible for any system to operate in a thermodynamic cycle
and deliver a new amount of energy by work to its surroundings while receiving energy by heat transfer

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from a single thermal reservoir. The hot streams cannot transfer all of their energy to heat the cold
stream. There must be some waste heat as a result of the heat transfer process.

Conservation of Mass
For a steady state system, the mass flow rate entering the control volume is equal to that exiting the
control volume. For the control volumes that have multiple hot streams entering the feed water heaters,
the mass flowrates are added together to determine the total inlet flow. The sum of all of the inlet
stream flowrates must be equal to the outlet stream flowrate since mass cannot be destroyed.

Heat Capacity
Enthalpy is the total energy of a system, which is determined by the sum of the internal energy and the
product of pressure and volume. Steam data is plotted on a temperature enthalpy diagram, called the
composite curve. The plot can be shifted, using the shifted temperatures, to determine the pinch point
because only the change in enthalpy between the inlet and outlet streams is needed. The heat capacity
flowrate and the heat load are used to determine the heat transfer characteristics of the system and the
required external utilities. The heat capacity flowrate and the heat load are calculated for all of the
temperature intervals. The heat capacity flowrate is the mass flowrate multiplied by the enthalpy of the
fluid for the given temperature range.

The heat load is the difference in enthalpy between the supply and target stream properties and is the
maximum amount of heat that could be transferred to or from a stream in a given temperature range.
The heat load is important because it determines how much heat transfer is possible between given
streams and how much external heating or cooling is required.

Problem Table Analysis

The problem table method is developed to allow for the maximum possible amount of heat exchange
within each temperature interval. The method is used for existing systems so that any hot and cold
streams can be matched together. There would be little flexibility for improvement of a heat exchanger
network if streams that are already matched via the current heat exchanger network were used in the
1 1
analysis. Shifted temperatures ( below hot stream and above cold stream ) are used to
2 2
ensure that exists between all hot and cold streams to adhere to the Second Law of
Thermodynamics.

Composite Curves
The composite curve is a way to incorporate all of the hot and cold streams onto a temperature-enthalpy
diagram. The maximum amount of heat recovery and hot and cold utilities can be found from the hot and
cold composite curves. The maximum amount of heat recovery, from the excess steam from the turbines
and from the cold feed water, is the area of overlap between the hot and cold composite curves (from
the upward arrow at the start of the cold composite to the downward arrow at the end of the hot
composite). The gap between the start of the hot and cold composite curves is the minimum cold utility
required and the gap between the end of the hot and cold composite curves is the minimum hot utility
required.

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 Shifted Composite Curve
The composite curves are also plotted using the shifted temperatures. The shifted composite curves
touch at the pinch point. The problem is divided on either side of the pinch point. Above the pinch point,
the cold flow is greater than the hot flow and the hot utilities must be supplied to make up the
difference. The cold composite extends farther along the x-axis (heat flow) than the hot composite,
therefore requiring a heating duty. Below the pinch point, the hot flow is greater than the cold flow and
cold utilities must be supplied. The cold composite curve trails the hot composite, requiring an external
cooling duty. Using shifted temperatures does not affect the values of the heat recovery, cooling duty or
heating duty, because the hot composite is being shifted down and the cold composite is being shifted up
by the same value.

Grand Composite Curve

The grand composite curve, shown in Figure 5, is a graph of the net heat flow (utility requirement) versus
the shifted temperature. The GCC is used for setting multiple utility targets. The shifted composite
1 1
curves ensure that is maintained (by using less than hot temperatures & greater
2 2
than cold temperatures) at all points. The x-axis of the GCC shows the utility heating or cooling required.
The pinch point is the location where the net heat flow is zero. The net heat flow values at the two
endpoints of the graph are the external heating and cooling duties that are required for optimum heat
transfer within the HEN. The curve also shows the temperatures at which heating and cooling are
required. When the pinch occurs at one end of the curve, it is referred to as a threshold problem.

Tmin and Trade offs

The minimum temperature difference between the hot and cold composite curves affects the pinch
temperature, the required external utilities, and the size of the heat exchangers. However, only the heat
exchangers that exist at the pinch point need to operate at because this is the most constrained
area of the HEN.

The heat exchanger area is roughly inversely proportional to the temperature difference. However, low
values of can result in large and costly heat exchangers. The hot utility required increases as the
heat exchanger area decreases. While there are cost savings involved with decreasing the physical area of
the heat exchanger, there are high energy costs associated with an increase in hot utilities. The optimum
must be selected for the best cost savings. The optimum can be selected by matching the
capital cost and the energy cost to determine the minimum cost for new designs. The point at which the
energy cost and the heat exchanger cost (surface area) are equal identifies the optimal .

As is increased, the difference between the hot and cold composite curves increases, which
increases the heat required by external utilities. The heating and cooling duties increase as the hot and
cold composite curves are separated by a larger .

Design of the Heat Exchanger Network

The design philosophy started at the heart of the onion with the reactor and moved out to the next layer,
the separation and recycle system. Acceptance of the major processing steps (reactors, separators and
recycles) in the inner two layers of the onion fixes the material and energy balance. Thus, the heating and
cooling duties for the next layer of the onion, the heat recovery system, are known. However, completing

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the design of the heat exchanger network is not necessary in order to assess the completed design.
Targets can be set for the heat exchanger network to assess the performance of the complete process
design without actually having to carry out the network design. These targets allow both energy and
capital cost for the heat exchanger network to be assessed. Moreover, the targets allow the designer to
suggest process changes for the reactor and separation and recycle systems to improve the targets for
energy and capital cost of the heat exchanger network.

Heat Exchange Stream Data for the flowsheet

() () () (. 1 )
Reactor 1 Feed Cold 50 190 350 2.5
Reactor 1 Product Hot 240 60 -540 3
Reactor 2 Feed Cold 100 210 440 4
Reactor 2 Product Hot 220 150 -140 2

For = 10

Reactor 1 Feed 55 195
Reactor 1 Product 235 55
Reactor 2 Feed 105 215
Reactor 2 Product 215 145

C C kW/K kW
235
1 20 3.0 60.0 surplus
215
2 20 1.0 20.0 surplus
195
3 50 -1.5 -75.0 demand
145
4 40 -3.5 -140.0 demand
105
5 50 0.5 25.0 surplus
55

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 Infeasible Feasible
Cascade Cascade
0 135
60 60
60 195
20 20
80 215
-75 -75
5 140
-140 -140
PINCH -135 0
25 25
-110 25

HOT PINCH = 110C

COLD PINCH = 100C

Minimum Hot Utility = 135.0 kW

Minimum Cold Utility = 25.0 kW

Curves:
Hot and Cold Composite Curves

300

250
Actual Temperature (C)

200

150

100

50

0
0 100 200 300 400 500 600 700 800 900

Heat Flow (kW)

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 Grand Composite

250

200
Shifted Temperature (C)

150

100

50

0
0 50 100 150 200 250
Net Heat Flow (kW)

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 Shifted Hot and Cold Composite Curves

250

200
Shifted Temperature (C)

150

100

50

0
0 100 200 300 400 500 600 700 800 900
Heat Flow (kW)

Grid Diagram
Interval 1 2 3 4 5
PINCH

Heat Flow Shifted

235

215

195

145

105

55

Stream Name mCp (kW/K)

(kW) Temp (C)

Reactor 1 Feed 440 4 COLD

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Reactor 1 Product 350 2.5 COLD

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Reactor 2 Feed 140 2 HOT

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Reactor 2 Product 540 3 HOT

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Actual Intervals Table

Actual Cold
T(i+1)-Ti CpHot dHHot Hot Duty CpCold dHCold
Temperature Duty
C kW/K kW kW kW/K kW kW
240 680.0
20 3.0 60.0 0.0 0.0
220 620.0
10 5.0 50.0 0.0 0.0
210 570.0 815.0
20 5.0 100.0 4.0 80.0
190 470.0 735.0
40 5.0 200.0 6.5 260.0
150 270.0 475.0
50 3.0 150.0 6.5 325.0
100 120.0 150.0
40 3.0 120.0 2.5 100.0
60 0.0 50.0
10 0.0 0.0 2.5 25.0
50 25.0

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 For = 20

Reactor 1 Feed 60 200
Reactor 1 Product 230 50
Reactor 2 Feed 110 220
Reactor 2 Product 210 140

+
C C kW/K kW
230
1 10 3.0 30.0 surplus
220
2 10 -1.0 -10.0 demand
210
3 10 1.0 10.0 surplus
200
4 60 -1.5 -90.0 demand
140
5 30 -3.5 -105.0 demand
110
6 50 0.5 25.0 surplus
60
7 10 3.0 30.0 surplus
50

Infeasible Feasible
Cascade Cascade

0 165
30 30
30 195
-10 -10
20 185
10 10
30 195
-90 -90
-60 105
-105 -105
PINCH -165 0
25 25
-140 25
30 30
-110 55

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HOT PINCH = 120C

COLD PINCH = 100C

Minimum Hot Utility = 165.0 kW

Minimum Cold Utility = 55.0 kW

Curves:

Hot and Cold Composite Curves

300

250
Actual Temperature (C)

200

150

100

50

0
0 100 200 300 400 500 600 700 800 900

Heat Flow (kW)

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 Grand Composite

250

200
Shifted Temperature (C)

150

100

50

0
0 50 100 150 200 250
Net Heat Flow (kW)

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 Shifted Hot and Cold Composite Curves

250

Grid200
Diagram
Interval 1 2 3 4 5 6 7
PINCH

Heat Flow Shifted

230

220

210

200

140

110

60

50
Shifted Temperature (C)

Stream Name mCp (kW/K)

(kW) Temp (C)
150

Reactor 2 Feed 440 4 COLD

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Reactor 1 Feed 350 2.5 COLD

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Reactor 2 Product 140 2 HOT

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100

Reactor 1 Product 540 3 HOT
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50

0
0 100 200 300 400 500 600 700 800 900
Heat Flow (kW)

Grid Diagram
Interval 1 2 3 4 5 6 7
PINCH

Heat Flow Shifted

230

220

210

200

140

110

60

50

Stream Name mCp (kW/K)

(kW) Temp (C)

Reactor 2 Feed 440 4 COLD

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Reactor 1 Feed 350 2.5 COLD

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Reactor 2 Product 140 2 HOT

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Reactor 1 Product 540 3 HOT

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Actual Intervals Table

Actual Cold
T(i+1)-Ti CpHot dHHot Hot Duty CpCold dHCold
Temperature Duty
C kW/K kW kW kW/K kW kW
240 680.0
20 3.0 60.0 0.0 0.0
220 620.0
10 5.0 50.0 0.0 0.0
210 570.0 845.0
20 5.0 100.0 4.0 80.0
190 470.0 765.0
40 5.0 200.0 6.5 260.0
150 270.0 505.0
50 3.0 150.0 6.5 325.0
100 120.0 180.0
40 3.0 120.0 2.5 100.0
60 0.0 80.0
10 0.0 0.0 2.5 25.0
50 55.0

Heat Exchanger Network for = 10

Several heat exchanger networks are discussed in the following section. Among all the designs, feasible
and best design is chosen for further calculation.

Blue ones represent coolers.

Red ones represent heaters.
White ones represent feasible process-process heat exchangers.
Yellow ones represent infeasible process-process heat exchangers.

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 110.0 C
XP = 0.0 kW

25.0 kW
25.0 C 20.0 C
Cooling Water

390.0 kW 125.0 kW
240.0 C 110.0 C 68.3 C
60.0 C
Reactor 1 Product

140.0 kW
220.0 C 150.0 C
Reactor 2 Product

50.0 kW
210.0 C 197.5 C
100.0 C
Reactor 2 Feed

85.0 kW
190.0 C 156.0 C 100.0 C
50.0 C
Reactor 1 Feed

250.0 C 249.4 C
249.0 C
HP Steam

100.0 C
XP = 0.0 kW
 110.0 C
XP = 0.0 kW

25.0 kW
25.0 C 20.0 C
Cooling Water

390.0 kW 125.0 kW
240.0 C 110.0 C 68.3 C 60.0 C
Reactor 1 Product

50.0 kW 90.0 kW
220.0 C 195.0 C 150.0 C
Reactor 2 Product
210.0 C 197.5 C 100.0 C
Reactor 2 Feed

135.0 kW
190.0 C 136.0 C 100.0 C 50.0 C
Reactor 1 Feed

250.0 C 249.0 C
HP Steam

100.0 C
XP = 0.0 kW
 25.0 C 20.0 C
Cooling Water

390.0 kW 150.0 kW
240.0 C 110.0 C
60.0 C
Reactor 1 Product

140.0 kW
220.0 C 150.0 C
Reactor 2 Product

50.0 kW
210.0 C 197.5 C
100.0 C
Reactor 2 Feed

60.0 kW
190.0 C 166.0 C 110.0 C
50.0 C
Reactor 1 Feed

250.0 C 249.5 C
249.0 C
HP Steam
 25.0 C 20.0 C
Cooling Water

390.0 kW 150.0 kW
240.0 C 110.0 C 60.0 C
Reactor 1 Product

50.0 kW 90.0 kW
220.0 C 195.0 C 150.0 C
Reactor 2 Product

210.0 C 197.5 C 100.0 C

Reactor 2 Feed

110.0 kW
190.0 C 146.0 C 110.0 C 50.0 C
Reactor 1 Feed

250.0 C 249.0 C
HP Steam
 Discussion on feasible design
First design is chosen primarily because in other designs due to the presence of temperature cross in the
T-H plot, the design of heat exchanger become infeasible. And due to this reason only, the criteria of
minimum number of heat exchangers cant be fulfilled. The other type of designs concerning the use of
medium and low pressure steam is discussed in the next section.

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 PART-II

Improvement of Design and Target Analysis 24

New Design 5 25

Theory of Area Targeting 26

Necessary curves 27

Acronyms
GCC Grand Composite Curve
SCC Shifted Composite Curve
HEN Heat Exchanger Network
SG Stream Generator
LP Low Pressure
HP High Pressure
MP Medium Pressure
BGCC Balanced Grand Composite Curve
BCC Balanced Composite Curve
BSCC Balanced Shifted Composite Curve

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 IMPROVEMENT OF DESIGN AND TARGET ANALYSIS

Introduction of medium pressure steam

To improve the design further a medium pressure steam is introduced in the design and the design is
improved further by replacing the high pressure steam by medium pressure steam at temperature 175
But after going through the cost analysis, we can say that the heating cost has decreased but in the same
time, capital cost has increased since we placed the medium pressure steam near the pinch. So, for
further cost analysis, we have two designs.
The next design is shown in the next page.

Network Performance
For Design 1
HEN % of Target
Heating(kW) 135 100
Cooling(kW) 25 100
Number of units 6 100

For Design 2
HEN % of Target
Heating(kW) 135 100
Cooling(kW) 25 100
Number of units 6 100

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 25.0 kW
25.0 C 20.0 C
Cooling Water

390.0 kW 125.0 kW
240.0 C 110.0 C 68.3 C
60.0 C
Reactor 1 Product

140.0 kW
220.0 C 150.0 C
Reactor 2 Product

50.0 kW
210.0 C 197.5 C
100.0 C
Reactor 2 Feed

85.0 kW
190.0 C 134.0 C 100.0 C
50.0 C
Reactor 1 Feed

250.0 C 249.0 C
HP Steam

175.0 C 174.0 C
MP Steam

125.0 C 124.0 C
LP Steam
 Theory of Area targeting
Area targeting is a vital component in the determination of the heat exchanger network capital cost and
thus plays an important role in capital energy trade off to determine the optimum .

Balanced Composite Curves

Composite curves, not only provide information about energy targets but also helps in predicting heat
transfer area of the heat exchanger network. As the heat exchanger network includes heat exchangers
which transfers heat from utilities, utility streams must also be made a part of composite curves before it
is used for area targeting. Such composite curves which include utility streams are called Balanced
Composite Curve. The utility demand for balanced composite curves is zero as the hot balance composite
curve is in heat balance with cold balance composite curve.

Calculation of Total Heat Transfer Area

The balance composite curve can be divided into vertical enthalpy intervals from 1 to. In each section of
the vertical enthalpy interval, the bounded sections of hot and cold composite curves resemble with
temperature profiles of counter-current heat transfer. Thus if overall heat transfer coefficient, , of this
interval( say ) is known then heat transfer area of section will be given by denoted by the
expression:

=

The total heat transfer area of the network based on vertical heat transfer,


= =

=1 =1

The minimum total area could be taken as the sum of the areas of all such heat exchangers from all such
enthalpy intervals as shown below:

1
= =

=1 =1 =1

= ( ) + ( )

=1

The above equations can be used to target heat transfer area, within 10% of the actual minimum of the
Heat Exchanger Network(HEN) on the basis of a vertical heat exchange model if film transfer coefficients
vary from streams to stream. However, if variations are large, it does not predict true minimum area of

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 HEN. If film heat transfer coefficients vary significantly, then nonvertical matching is required to achieve
minimum area.

Necessary Curves

Hot and Cold Balanced Composite Curves

300

250
Actual Temperature (C)

200

150

100

50

0
0 100 200 300 400 500 600 700 800 900
Heat Flow (kW)

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 Balanced Grand Composite

300

250
Shifted Temperature (C)

200

150

100

50

Net Heat Flow (kW)

0
0 50 100 150 200 250

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 Shifted Hot and Cold Balanced Composite Curves

300

250

200
Shifted Temperature (C)

150

100

50

0
0 100 200 300 400 500 600 700 800 900
Heat Flow (kW)

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