Episode 60 : Pinch Diagram

and Heat Integration

SAJJAD KHUDHUR ABBAS

Ceo , Founder & Head of SHacademy
Chemical Engineering , Al-Muthanna University, Iraq
Oil & Gas Safety and Health Professional OSHACADEMY
Trainer of Trainers (TOT) - Canadian Center of Human
Development
 Introduction of Process Integration

Pinch Diagram and Heat Integration

Reference: Notes from course on Modelling, design and

control for process integration, CAPEC, August 2000 (R.
Dunn)
Process Integration Tools Allow Analysis of the Enterprise
The optimal allocation of mass and energy within a unit operation, process and/or site.
Optimal allocation can be based on economic, environmental or other important objectives.

Heating Power Pressure

Cooling
Feed Stock Products
Chemical
Solvents Plant By-Products
(Enterprise)
Effluents
Catalysts

Material for Utilities Spent Materials

(Water, Coal)
Heating Power Pressure
Cooling

Mass Integration (Mass Exchange Network MEN)

Energy Integration (Heat Exchange Network HEN)
 Process Integration Techniques
Mass Reactive Mass
Mass Exchange ExchangeNetworks
Exchange Networks
Heat
Networks with Regeneration
Exchange
(MENs) (REAMENs) (MEN/REGEN)
Networks Combined Heat and
(HENs) Reactive Mass
Exchange Networks
(CHARMENs)
Pervaporation
Networks Process
Process Waste Interception
(PERVAPs)
Integration
Integration and Allocation
Networks
Reverse
(WINs)
Osmosis
Networks
(RONs) Energy-Induced
Separation
Heat-Induced Heat-Induced Networks
Waste Minimization Energy-Induced Separation
Waste Minimization (EISENs)
Networks Networks
(HIWAMINs) Networks
(EIWAMINs) (HISENs)
 Heat Exchange Network (HEN)
(Linnhoff, Grossmann et al, 1978-Present)
A Heat Exchange Network is a System of One or More Heat Exchangers
Hot and Cold Utilities

Hot Streams In
Heat
Exchanger
Network

Cold Streams In

Plant Products
Raw Materials &
Unit Operations By-Products

Cold Streams Out

Hot Streams Out

Want to Identify:
Optimal matching between hot and cold streams to
minimize utility consumption
Minimum number of heat exchangers needed 4
 Consider the problem of two hot stream and two cold streams:

Table 1*

Stream Q available
No. Condition FCp, BTU/(hroF) Tin Tout 103 BTU/hr

1 Hot 1000 250 120 130

2 Hot 4000 200 100 400
3 Cold 3000 90 150 -180
4 Cold 6000 130 190 -360
-10

First Law Analysis (Conservation of Energy):

1000 BTU
Q F Cp T (250 120)o F 130x103 BTU / hr
1 1 1 1
hr o F

4000 BTU
Calculate Q3 and Q4
Q F Cp T (200 100) F 400x10 BTU / hr
o 3

2 2 2 2 o
hr F

Therefore, 10x103 BTU/hr must be supplied from utilities (if there are no restrictions on temperature driving force)

How can we check driving force restrictions? Second Law Analysis (You can not transfer heat from a lower
temperature to a higher temperature)

5
*Ref. Douglas, 1988, Conceptual Design of Chemical Processes, McGraw-Hill Publishers, p. 218.
Shifted Temperature Scales (using Table 1 data):
Hot Temperature Scale Cold Temperature Scale
250 240

200 190

150 140

100 90

Sources Sinks

These streams These streams

need to be cooled need to be heated
Temperature Interval Diagram (TID)
Hot Temperature Scale Cold Temperature Scale

250 240

200 190

160 150

140 130

120 110
100 90
 Net Energy Required at Each Interval
Hot Temperature Scale Cold Temperature Scale Heat Duty Within Intervals
Interval, i
FCp 1000 4000 250 240 3000 6000 1000 Q

1 50

200 190

2 -40
160 150

140 3 130 -80

120 4 110 40

100 5 90 20

Total = -10

Qi (FCp) hot,i
(FCp) cold ,i Ti
Therefore,
Q1 (1000)(250 200) 50x103
Q2 (1000 4000 6000)(200 160) 40x103
Q3 (1000 4000 3000 6000)(160 140) 80x103
Heat Transfer to and from Utilities for Each Temperature Interval
Hot Temperature Scale Cold Temperature Scale

250 240

50
200 190

Hot -
40

Cold
160 Utility Utility 150
140 130

120 110
100 20 90
Cascade Diagram
Hot Temperature Scale Cold Temperature Scale

250 240

50

200 50 190

Hot -40 Cold

160 Utility 10 Utility 150
70
-80 Pinch
140 130
0
40 40
100 20 60 90
Hot Composite Curve
Table 2*

Hot streams, oF Cumulative H

T=100 H0=0 0
T=120 H1=4000(120-100)=80,000 80,000
T=140 H2=(1000+4000)(140-120)=100,000 180,000
T=160 H3=(1000+4000)(160-140)=100,000 280,000
T=200 H4=(1000+4000)(200-160)=200,000 480,000
T=200 H5=1000(250-200)=50,000 530,000

Since FCp values are constant, we could have replaced the calculation for H2, H3, H4 with a single expression:
H2,3,4=(1000+4000)(200-120)=400,000

Temperature
(oF) Plot Becomes the Hot Composite Curve

Enthalpy (1000 BTU/hr) 11

*Ref. Douglas, 1988, Conceptual Design of Chemical Processes, McGraw-Hill Publishers, p. 218.
 Hot Composite Curve

270
250
230
Temperature (deg F)
210
190
170
150
130
110
90
0 100 200 300 400 500 600
Enthalpy, 1000 BTU/hr
Cold Composite Curve
Table 2.3*

Cold streams, oF Cumulative H

T=90 H0=60,000 60,000
T=130 H1=3000(130-90)=120,000 180,000
T=150 H2=(3000+6000)(150-130)=180,000 360,000
T=190 H3=6000(190-150)=240,000 600,000

Temperature
(oF) Plot Becomes the Cold Composite Curve

Enthalpy (1000 BTU/hr)

*Ref. Douglas, 1988, Conceptual Design of Chemical Processes, McGraw-Hill Publishers, p. 218.
 Cold Composite Curve

210

190
Temperature (deg F)

170

150

130

110

90
0 100 200 300 400 500 600 700
Enthalpy, 1000 BTU/hr
 Hot Composite Stream
Cold Composite Stream at 10 deg F
Composite Curves minimum temperature driving force

270
250
Temperature, deg F 230
210
190
170
150
130
110
90
0 200 400 600
Enthalpy, 1000 BTU/hr
Computer Aided process Engineering - Lecture 11 (R. Gani)
 Hot Composite Stream
Cold Composite Stream at 10 deg F
Composite Curves minimum temperature driving force
Cold Composite Stream at 20 deg F
minimum temperature driving force

270
250
Temperature, deg F 230
210
190
170
150
130
110
90
0 200 400 600
Enthalpy, 1000 BTU/hr
Computer Aided process Engineering - Lecture 11 (R. Gani)
 Composite Pinch Diagram

Pinch or
Tminimum

Temperature Minimum Minimum

Amount of Amount of
Cold Utility Hot Utility
Required Required

Process to Process
Heat Integration

Enthalpy
Computer Aided process Engineering - Lecture 11 (R. Gani)
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