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72

Heat Exchanger Network Design:

The Pinch Design Method

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73

Design of Individual Processes

for Maximum Energy Recovery
Divide the process at the pinch

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74

Design of Individual Processes

for Maximum Energy Recovery
The feasibility of heat transfer

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75

Design of Individual Processes

for Maximum Energy Recovery
Cross-pinch heat transfer: Actual = Target + XP

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76

Design of Individual Processes

for Maximum Energy Recovery
Cold utility above the pinch

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77

Design of Individual Processes

for Maximum Energy Recovery
Hot utility below the pinch

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Design of Individual Processes

for Maximum Energy Recovery

Design Rule
Do Not Transfer Heat Across the Pinch
Do not use steam below
Do not use cooling water above
Do not recover process heat across

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Typical Grid Diagram

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Typical Grid Diagram

Rules for Construction
Hot streams run left to right
Cold streams run right to left
Hot streams on top; Cold streams on bottom

Hot utility = H
Cold utility = C
Heat exchanger between streams =

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Where Is The Pinch ?

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Pinch Is Easily Shown

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Separate Above/Below-Pinch Regions

83

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84

Number of Heat Exchanger Units

Graph any collection of points in which some pairs of points are
connected by lines

Path a sequence of distinct lines which are connected to each

other

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Number of Heat Exchanger Units

A graph forms a single component if any two points are joined by
a path
Loop

a path which begins and ends at the same point (CGDHC)

If two loops have a line in common, they can be linked to form

a third loop by deleting the common line (BGCEB + CGDHC
BGDHCEB)
The number of independent loops for a graph:
NUNITS = S + L C
NUNITS
S
L
C

=
=
=
=

#
#
#
#

of
of
of
of

matches or units (lines in graph theory)

streams including utilities (points in a graph)
independent loops
components

A single component and loop-free:

NUNITS = S 1

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Number of Heat Exchanger Units

If the problem has a pinch:
NUNITS = (Sabove pinch 1) (Sbelow pinch 1)
To target the number of units for pinched problems, the streams
above and below the pinch must be counted separately
(NUNITS = (5 1) + (4 1) = 7)

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The Pinch Design Method

Stream
1.
2.
3.
4.

Reactor
Reactor
Reactor
Reactor

1
1
2
2

feed
prod
feed
prod

Type

Supply Temp.
TS (oC)

Target Temp.
TT (oC)

H
(M W )

Heat Capacity Rate

mC
p(M W/oC)

Cold
Hot
Cold
Hot

20
250
140
200

180
40
230
80

+32.0
31.5
+27.0
30.0

0.20
0.15
0.30
0.25

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The Pinch Design Method

Known
No exchanger should have a temp di. smaller than Tmin
No heat transfer across the pinch by
process-to-process heat transfer
inappropriate use of utilities

Composite
curves:

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The Pinch Design Method

Start at the Pinch
(Tmin exists between all hot/cold streams, the most constrained region)

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The Pinch Design Method

Divide at the pinch

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The Pinch Design Method

CP Inequality for Individual Matches
Above Pinch: if CPH >CPC

infeasible!

Th = 162o (suppose)
Hh = 0.25(162150)
= 3 MW
MW
Tc = 140 + 0.23 MW/
o
C
Tmin

=
>
=
=

155oC
Th Tc
162 155
7oC

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The Pinch Design Method

CP Inequality for Individual Matches
Above Pinch: if CPH CPC

feasible

Th = 162o (suppose)
Hh = 0.25(162150)
= 3 MW
MW
Tc = 140 + 0.33 MW/
o
C
Tmin

=
<
=
=

150oC
Th Tc
162 150
12oC

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93

The Pinch Design Method

CP Inequality for Individual Matches
Below Pinch: if CPH <CPC

infeasible!

Tc = 125o (suppose)
Hc = 0.2(140125)
= 3 MW
MW
Th = 150 .153 MW/
o
C
Tmin

=
>
=
=

130oC
Th Tc
130 125
5oC

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94

The Pinch Design Method

CP Inequality for Individual Matches
Below Pinch: if CPH CPC

feasible

Tc = 125o (suppose)
Hc = 0.2(140125)
= 3 MW
MW
Th = 150 .253 MW/
o
C
Tmin

=
<
=
=

138oC
Th Tc
138 125
13oC

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95

The Pinch Design Method

CP Inequalities: Summary
for temperature dierences to increase moving away from the pinch
Above Pinch: CPH CPC

Below Pinch: CPH CPC

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96

The Pinch Design Method

The CP Table
Cold utility must not be used above the pinch
hot streams must be cooled to pinch temp. by recovery
hot utility can be used on cold streams above the pinch

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The Pinch Design Method

The Tick-O Heuristic (above pinch)
Now we have identied feasible matches
How big should we make them ?

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The Pinch Design Method

The Tick-O Heuristic (above pinch)
Maximize loads to tick o streams
to keep capital costs down

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99

The Pinch Design Method

The Tick-O Heuristic (above pinch)
Then ll in the rest

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100

The Pinch Design Method

The Tick-O Heuristic (above pinch)
Then ll in the rest

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101

The Pinch Design Method

The Tick-O Heuristic (below pinch)
Maximize loads to tick o streams
to keep capital costs down

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102

The Pinch Design Method

The Tick-O Heuristic (below pinch)
Maximize loads to tick o streams
to keep capital costs down

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103

The Pinch Design Method

The Tick-O Heuristic (below pinch)
Then ll in the rest

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104

The Pinch Design Method

The Tick-O Heuristic (below pinch)
Then ll in the rest

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105

The Pinch Design Method

The Tick-O Heuristic (below pinch)
Note: one match violates CP rules
But, it is away from the pinch and therefore feasible

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The Pinch Design Method

The Tick-O Heuristic: Summary
To tick o a stream, individual units are made as large as possible
the smaller of the two heat duties on the streams being matched

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107

The Pinch Design Method

The Completed Design

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108

The Pinch Design Method

Network Design Using Two Steam Levels

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109

The Pinch Design Method

Network Design Using Two Steam Levels

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110

The Pinch Design Method

Network Design Using Two Steam Levels

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111

The Pinch Design Method: Summary

Divide the problem at the pinch into separate problems
Design separate problems, started at the pinch, moving away
Temperature feasibility requires constraints on CP values to be
satised for matches between streams at the pinch
Loads on individual units are determined using the kick-o heuristic
to minimize # of units
Away from the pinch: more freedom, use judgment and process
knowledge

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Stream Splitting: # of Streams

Cold utility must not be used
above the pinch
All hot streams must be cooled to
pinch temperature by heat recovery
Splitting cold streams
Above Pinch: SH SC

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Stream Splitting: # of Streams

Hot utility must not be used
below the pinch
All cold streams must be heated to
pinch temperature by heat recovery
Splitting hot streams
Below Pinch: SH SC

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Stream Splitting: CP Inequality

Above Pinch: CPH CPC

Hot stream with larger CP values
Split into smaller parallel
hot streams
(opt ow rates ?)

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Stream Splitting: CP Inequality

Below Pinch: CPH CPC

Cold stream with larger CP values
Split into smaller parallel
cold streams
(opt ow rates ?)

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116

Stream-Splitting Algorithms
Above the Pinch

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Stream-Splitting Algorithms
Below the Pinch

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118

Design of Individual Processes

for Maximum Energy Recovery

Pinch Design Rule

Do Not Transfer Heat Across the Pinch
Divide at the PINCH
Start at the PINCH and move away
Observe the PINCH rules:
Do not use steam below
Do not use cooling water above
Do not recover process heat across

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119

Pinch Analysis and Process Integration

Case Study

Crude Preheat Train

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120

PI Case Study: Crude Preheat Train

Original Process

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121

PI Case Study: Crude Preheat Train

Original Process

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122

PI Case Study: Crude Preheat Train

Original Process

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123

PI Case Study: Crude Preheat Train

Original Process

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PI Case Study: Crude Preheat Train

Original Process

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PI Case Study: Crude Preheat Train

Original Process

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PI Case Study: Crude Preheat Train

Original Process

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127

PI Case Study: Crude Preheat Train

Original Process

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PI Case Study: Crude Preheat Train

Contractors Design

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PI Case Study: Crude Preheat Train

Hot/Cold Streams

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PI Case Study: Crude Preheat Train

Network Grid Diagram: Contractors Design

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PI Case Study: Crude Preheat Train

Network Grid Diagram with Increased HEs

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PI Case Study: Crude Preheat Train

Comparison of UA Values for Di. Network Designs
Energy
Max split
UA for N1
N2
3
4
5
6
7
8
9
10
UAAll HEs
UAAir cooler
UATotal

Contractors
design
81.9
2
0.288
0.159
0.152
0.462
0.196
0.132
0.022
0.111
1.522
0.550(mod)
2.072

Inc. area
design
68.0
2
0.380(new)
0.230(new)
0.393(mod)
0.512(mod)
0.150
0.462
0.195
0.115
0.022
0.165(mod)
2.624
0.550(mod)
3.174

MER
design
61.1
4
0.393(new)
0.714(new)
0.549(mod)
0.286(mod)
0.462
0.293(mod)
0.454(mod)
0.022
0.180(mod)
3.353
0.550(mod)
3.903

Evolved
design 1
68.0
4
0.332(new)
0.337
0.412(mod)
0.147
0.462
0.198
0.241(mod)
0.022
0.111
2.262
0.550(mod)
2.812

Evolved
design 2
68.0
3
0.380(mod 5)
0.210(new)
0.337
0.476(mod)
0.506
0.193
0.234(mod)
0.022
0.111
2.421
0.392
2.813

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133

PI Case Study: Crude Preheat Train

Composite Curves and Grand composite Curve

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134

PI Case Study: Crude Preheat Train

Network Grid Diagram: Contractors Design

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135

PI Case Study: Crude Preheat Train

Contractors Network Showing Pinch Temperature

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136

PI Case Study: Crude Preheat Train

Stream Grid Above The Pinch

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137

PI Case Study: Crude Preheat Train

Complete MER Network Above The Pinch

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138

PI Case Study: Crude Preheat Train

Stream Grid Below The Pinch

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139

PI Case Study: Crude Preheat Train

Complete MER Network Below The Pinch

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140

PI Case Study: Crude Preheat Train

Combined MER Network for Complete Process

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141

PI Case Study: Crude Preheat Train

First Relaxation from MER Design

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142

PI Case Study: Crude Preheat Train

Elimination of Four-way Stream Split

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143

PI Case Study: Crude Preheat Train

Second Evolution of Network Design

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144

PI Case Study: Crude Preheat Train

Comparison of UA Values for Di. Network Designs
Energy
Max split
UA for N1
N2
3
4
5
6
7
8
9
10
UAAll HEs
UAAir cooler
UATotal

Contractors
design
81.9
2
0.288
0.159
0.152
0.462
0.196
0.132
0.022
0.111
1.522
0.550(mod)
2.072

Inc. area
design
68.0
2
0.380(new)
0.230(new)
0.393(mod)
0.512(mod)
0.150
0.462
0.195
0.115
0.022
0.165(mod)
2.624
0.550(mod)
3.174

MER
design
61.1
4
0.393(new)
0.714(new)
0.549(mod)
0.286(mod)
0.462
0.293(mod)
0.454(mod)
0.022
0.180(mod)
3.353
0.550(mod)
3.903

Evolved
design 1
68.0
4
0.332(new)
0.337
0.412(mod)
0.147
0.462
0.198
0.241(mod)
0.022
0.111
2.262
0.550(mod)
2.812

Evolved
design 2
68.0
3
0.380(mod 5)
0.210(new)
0.337
0.476(mod)
0.506
0.193
0.234(mod)
0.022
0.111
2.421
0.392
2.813

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145

PI Case Study: Crude Preheat Train

Original Process

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146

PI Case Study: Crude Preheat Train

Contractors Design

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147

PI Case Study: Crude Preheat Train

Final Selected Design

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148

PI Case Study: Crude Preheat Train

Conclusions
The Pinch Design Method generated a network which was
substantially better than that obtained by any previous methods of
heat exchanger network design.
The targeting stage gives a rapid initial assessment of the scope
for change and the likely diculties which will be encountered in
obtaining a solution.
The network design method can be used systematically to produce
good revamp designs, even where the existing heat exchanger
network is complex.
It allows a productive interaction with the engineers experience
(a good example is the use of the pump-around in the preferred
solution).

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149

PI Case Study: Crude Preheat Train

Conclusions
Designs produced by proper use of the method are elegant,
sometimes yielding both energy and capital savings.
A higher degree of process integration does not necessarily
cause control problems. If the integration is well balanced the
controllability can be enhanced.
Parallel stream splitting is a practical tool for improving energy
recovery and operability.
The Pinch Design Method can be employed to give good designs
in rapid time and with minimum data.