HEN Pinch Analysis 1

Pinch Analysis
© 2007 G.P. Towler / UOP. For educational use in conjunction with

Sinnott & Towler Chemical Engineering Design only. Do not copy
Chemical Engineering Design
What is Pinch Analysis?
• Pinch Analysis is a method to

– Determine utility requirements
– Estimate optimal exchanger requirements
– Provide an overview of energy flow in the entire
process or across the whole site
– Obtain an overall view of the whole steam/power
utility system
• All this without designing any heat exchangers.

Heat Integration

Pinch Analysis Overview
• Basic definitions
• Process composite curves

– Combining data to get an overview of process energy needs
• Data extraction
– Common pitfalls in the analysis
• Tools for pinch analysis
• Process modification

Simple Heat Exchange Network
• Look at a simple system:
T1
Hot Stream
Steam
t1 t2 t3
Cold Stream
T2
T3
CW
• How can we determine the optimal values for

T2 and t2?

• We can plot temperature vs. duty:
Qhot
t3
T1
Temperature
DTmin t2
T2
T3
t1
Qcold Qrec
Duty

• The maximum possible heat recovery is when the two
curves “pinch” and ΔTmin = 0
Qhot min
DTmin= 0 t3
T1
TEMPERATURE
t2
T2
T3
t1
Qcold min
Qrec max
DUTY
• What happens as 
TTmin approaches 0?
– Hot utility (steam) consumption is the lowest.
– Cold utility (cooling water) consumption is the lowest.
– We still need three heat exchangers
• 1 process-
process-process exchanger.
• 1 process-
process-hot utility exchanger.
• 1 process-
process-cold utility exchanger.
• What is 
TTlm for the process-
process-process exchanger?
• How big is the process-

process-process heat exchanger?

• We can see that changing 
TTmin affects
– Utility requirements.
– Heat exchanger areas
• How can we find an optimum 

TTmin?
– Design and cost the system for a range of 
T
Tmin .
• Determine capital costs.
• Determine operating costs.
– Combine capital and operating costs to determine

an annualized cost
– Plot annualized cost vs. 
T
Tmin
– Select the minimum
DTmin OPTIMIZATION
140
120
100
Tmin opt
Cost (10 $/y)
80
6
60
40
20
0
0 20 DTmin 40 60
Utility Costs Annualized Capital Cost

Total Cost

Multi
Multi--stream Problems:
Composite Curves
• How do we handle multiple streams that have
temperature overlap?
• Stream data must be combined in such a way

as to represent the total energy sources and
total energy demands in each temperature
range.
• The pinch method creates what is called a

composite curve.
curve.

Composite Curves
• Consider a two stage reactor with reheat:
550° Rctr
Feed
#1 510° A 550°
Rctr
#2 520°
B 560°
To Next Reactor
Streams A and B have overlapping duties between 520° and 550°.

Composite Curves
• Multistage reactor example - stream data
Range T in T out Streams M*Cp Q
1 510 520 A 1 10
2 520 550 A 1 30
520 550 B 1 30
520 550 A+B 2 60
3 550 560 B 1 10
Plot T vs. Q for each temperature

range.

Composite Curves
• Multistage reactor example - composite curve
570
560
TEMPERATURE (T)
550
540
530
520
510
500
0 20 40 60 80 100
Duty (Q)

Composite Curves
• There is an easy way to plot the composite curves:
just add up the Q values over each range of T
570
560
TEMPERATURE (T)
550
540
530
520
510
500
0 20 40 60 80 100
Duty (Q)

Composite Curves for UOP Platforming
Process
1000
800
Temperature (F)
600
400
200
0
0 50 100 150 200 250
Duty (MMBtu/h)

Composite Curves
QH
1000
800
Temperature (F)
• We can set targets

600 Pinch for hot and cold
utilities using the
400 composites, while
paying attention to
200 the process pinch
QC
0
0 50 100 150 200 250
Duty (MMBtu/h)

Composite Curves
QH
1000
800
Temperature (F)
• Since the duty scale

600 Pinch is a difference in
enthalpy, we can
400 slide the composite
curves horizontally,
200 increasing or
QC
decreasing Tmin
0
0 50 100 150 200 250
Duty (MMBtu/h)

Composite Curves
QH
1000
800
Temperature (F)
600 Pinch • If we decrease ΔTmin

then our utility
400 targets are reduced
• What is the effect on
200
capital cost though?
QC
0
0 50 100 150 200 250
Duty (MMBtu/h)

Optimization of ΔTmin
• What happens as Tmin is increased?
– More heat exchangers are required (extra cost)
– Log mean temperature differences are
are greater
• Each heat exchanger is smaller
• The cost for each heat exchanger decreases (cost savings)
– More utilities are consumed

• Cooling water demand increases
• Steam demand increases
• Utility costs increase
• Note: hot utility increase = cold utility increase
• How do we decide on the appropriate Tmin?

– Same as the two-
two-stream problem
– Plot Total Annualized Cost vs. Tmin for the process
Optimization of ΔTmin
DTmin OPTIMIZATION
140
120
Tmin opt
100
Cost (10 $/y)
80
6
60
40
20
0
0 20 DT min 40 60
Utility Costs Annualized Capital Cost

Total Cost

Energy Costs
• Energy prices are often assumed to be well know
• In practice, energy prices are affected by:

• Commodity nature of fuels
• Fuel mix
• Flaring of waste products (“fuel value” vs. disposal cost)
• Capital cost implications of fuel substitution
• So the actual energy price varies with time and is

seldom properly captured

Capital Targets
• How do we get the capital cost without designing the
heat exchange network (HEN)?
Temperature Qhot
Qcold Qrec
Duty
Capital Targets
• Pinch analysis develops an area target based on
assumed counter-
counter-current heat transfer between the
composites in each segment
Qhot
7
Temperature
5 If we treat each
4
3 segment as a two
2 stream problem we
1
can develop a 1:1
(or 1:2) shell & tube
Qcold Qrec HX area
Duty
Capital Targets
• We can then plot area targets against ΔTmin
• We can also introduce a correlation for cost vs. area and

hence plot a capital target against ΔTmin
• Hence find optimum ΔTmin

140
120
Cost (106 $/y)

100
80
60
40
20
0
0 10 20 DT30
min
40 50 60
Utility Costs Annualized Capital Cost Total Cost

Thermodynamic Significance of the
Pinch
“pinch”
Qhot min
Temperature
Qrec max
Qcold min
Duty
• When the process is pinched it is

decomposed into two sub problems
Pinch Decomposition
Above the pinch
we only put in
“pinch”
Qhot min utility heat and
the process acts
Temperature
as a heat sink
Below the pinch we

only reject heat to cold
Qrec max
utility and the process
Qcold min acts as a heat source
Duty
• When the process is pinched it is

decomposed into two sub problems
Pinch Decomposition
• What if we put in extra heat above the pinch?
Qextra
“pinch”
Qhot min
Temperature
Qextra Heat sink is now out

of energy balance
and we have to
reject Qextra to a
Qrec max lower temperature
Qcold min
Duty

Pinch Decomposition
• What if we put in extra heat above the pinch?
Qextra
“pinch”
Qhot min
Temperature
Qextra
Now the heat

source is also out of
Qextra energy balance and
Qrec max we have to reject
Qcold min Qextra to cold utility
Duty

Pinch Decomposition
The overall effect is that both hot and cold utility are increased by
the amount of heat transferred across the pinch = Qextra
Qextra
“pinch”
Qhot min
Temperature
Qextra
Qextra
Qrec max
Qcold min
Duty
So a simple rule for achieving energy targets is don’t
transfer heat across the pinch!
Pinch Design Method
• Use composite curves to find the pinch temperature
• Optimize Tmin, making process changes
• Decompose the network design problem using the pinch

temperatures
• Design the Heat Exchanger Network (HEN) for each

subsystem separately:
– Transfer no heat “across” the pinch
– T > Tmin for all heat exchangers
– Start at the pinch and work outward

Data Extraction
• We need to extract the data from a flowsheet
to do the pinch analysis
Existing
Process
Flowsheet
Data
Pinch Analysis
New Design

Data Extraction
• But there is a catch:
Existing
Process
Too many constraints Flowsheet
from the existing
design
Data
Pinch Analysis
New Design

Data Extraction
• Usually the easiest way to start is by reading
the heat loads from the flowsheet
100º 150º
30º
70º 150º
10º 25º 25º S
H1 H2 H3
feed
filter
120º 200º
120º
150
T
70 How many streams
25 do we have?
10
H1 H2 H3 dH
Data Extraction
• What’s the problem with this approach?
100º 150º
30º
70º 150º
10º 25º 25º S
H1 H2 H3
feed
filter
120º 200º
120º
150
T We need to be very careful
70 that we do not miss phase
25 changes!
10
H1 H2 H3 dH
Data Extraction
• When we have a vaporization we need to
linearize. How do we do this?
150
T
70
25
10
H1 H2 H3 dH

Data Extraction
150
T
70
25
10
H1 H2 H3 dH
(A) Point to Point

Data Extraction
150
T
70
25
10
H1 H2 H3 dH
(B) Piecewise best fit

Data Extraction
150
T
70
25
10
H1 H2 H3 dH
(C) Above the line

Data Extraction
150
T
70
25
10
H1 H2 H3 dH
(D) Below the line

Data Extraction
• To be conservative we always linearize on the safe
side.
• You can always add more detail near to the pinch if

you are concerned about the accuracy of the
linearization
dH

Data Extraction
• Soft constraints
Why? & why not?
Storage Storage
240º 100º 240º 110º
Tank Tank
100º 110º
The constraint is “soft” and can be changed.

Good opportunity for process modification!

Data Extraction Rules
1. Don’t incorporate non-
non-essential features of the existing
design
2. Watch for phase changes
3. Linearize on the safe side
4. Extract data for isothermal mixing
5. Do not extract utilities
6. Adjust soft constraints to improve targets

Example
Given
Hot Streams Cold Streams

Acumulated Acumulated
Stream(s) Range Enthalpy
Enthalpy
T Stream(s) Range Enthalpy T
Enthalpy
0 50 0 40
2&3 500 500 150 6 200 200 90
1&3 550 1050 200 5&6 1200 1400 190
1 800 1850 300 4 500 1900 290

Example
Plot the composite curves (T vs Duty)
See Excel


HEN Pinch Analysis 1

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Pinch Analysis

© 2007 G.P. Towler / UOP. For educational use in conjunction with

• Pinch Analysis is a method to

• All this without designing any heat exchangers.

© 2007 G.P. Towler / UOP. For educational use in conjunction with

© 2007 G.P. Towler / UOP. For educational use in conjunction with

• Process composite curves

• Tools for pinch analysis

© 2007 G.P. Towler / UOP. For educational use in conjunction with

• How can we determine the optimal values for

© 2007 G.P. Towler / UOP. For educational use in conjunction with

© 2007 G.P. Towler / UOP. For educational use in conjunction with

• How big is the process-

© 2007 G.P. Towler / UOP. For educational use in conjunction with

• How can we find an optimum 

– Combine capital and operating costs to determine

Utility Costs Annualized Capital Cost

© 2007 G.P. Towler / UOP. For educational use in conjunction with

• Stream data must be combined in such a way

• The pinch method creates what is called a

© 2007 G.P. Towler / UOP. For educational use in conjunction with

Streams A and B have overlapping duties between 520° and 550°.

© 2007 G.P. Towler / UOP. For educational use in conjunction with

Plot T vs. Q for each temperature

© 2007 G.P. Towler / UOP. For educational use in conjunction with

© 2007 G.P. Towler / UOP. For educational use in conjunction with

© 2007 G.P. Towler / UOP. For educational use in conjunction with

© 2007 G.P. Towler / UOP. For educational use in conjunction with

• We can set targets

© 2007 G.P. Towler / UOP. For educational use in conjunction with

• Since the duty scale

© 2007 G.P. Towler / UOP. For educational use in conjunction with

600 Pinch • If we decrease ΔTmin

© 2007 G.P. Towler / UOP. For educational use in conjunction with

– More utilities are consumed

• How do we decide on the appropriate Tmin?

Utility Costs Annualized Capital Cost

© 2007 G.P. Towler / UOP. For educational use in conjunction with

• Energy prices are often assumed to be well know

• In practice, energy prices are affected by:

• So the actual energy price varies with time and is

© 2007 G.P. Towler / UOP. For educational use in conjunction with

• We can also introduce a correlation for cost vs. area and

• Hence find optimum ΔTmin

Cost (106 $/y)

Utility Costs Annualized Capital Cost Total Cost

© 2007 G.P. Towler / UOP. For educational use in conjunction with

• When the process is pinched it is

Below the pinch we

• When the process is pinched it is

Qextra Heat sink is now out

© 2007 G.P. Towler / UOP. For educational use in conjunction with

Now the heat

© 2007 G.P. Towler / UOP. For educational use in conjunction with

• Optimize Tmin, making process changes

• Decompose the network design problem using the pinch

• Design the Heat Exchanger Network (HEN) for each

© 2007 G.P. Towler / UOP. For educational use in conjunction with

© 2007 G.P. Towler / UOP. For educational use in conjunction with

© 2007 G.P. Towler / UOP. For educational use in conjunction with

© 2007 G.P. Towler / UOP. For educational use in conjunction with

(A) Point to Point