Chen CL
72
Heat Exchanger Network Design:
The Pinch Design Method
Chen CL
73
Design of Individual Processes
for Maximum Energy Recovery
Divide the process at the pinch
Chen CL
74
Design of Individual Processes
for Maximum Energy Recovery
The feasibility of heat transfer
Chen CL
75
Design of Individual Processes
for Maximum Energy Recovery
Cross-pinch heat transfer: Actual = Target + XP
Chen CL
76
Design of Individual Processes
for Maximum Energy Recovery
Cold utility above the pinch
Chen CL
77
Design of Individual Processes
for Maximum Energy Recovery
Hot utility below the pinch
Chen CL
78
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
Chen CL
79
Typical Grid Diagram
Chen CL
80
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 =
Chen CL
81
Where Is The Pinch ?
Chen CL
82
Pinch Is Easily Shown
Chen CL
Separate Above/Below-Pinch Regions
83
Chen CL
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
Chen CL
85
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
Chen CL
86
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)
Chen CL
87
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
Chen CL
88
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:
Chen CL
89
The Pinch Design Method
Start at the Pinch
(Tmin exists between all hot/cold streams, the most constrained region)
Chen CL
90
The Pinch Design Method
Divide at the pinch
Chen CL
91
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
Chen CL
92
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
Chen CL
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
Chen CL
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
Chen CL
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
Chen CL
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
Chen CL
97
The Pinch Design Method
The Tick-O Heuristic (above pinch)
Now we have identied feasible matches
How big should we make them ?
Chen CL
98
The Pinch Design Method
The Tick-O Heuristic (above pinch)
Maximize loads to tick o streams
to keep capital costs down
Chen CL
99
The Pinch Design Method
The Tick-O Heuristic (above pinch)
Then ll in the rest
Chen CL
100
The Pinch Design Method
The Tick-O Heuristic (above pinch)
Then ll in the rest
Chen CL
101
The Pinch Design Method
The Tick-O Heuristic (below pinch)
Maximize loads to tick o streams
to keep capital costs down
Chen CL
102
The Pinch Design Method
The Tick-O Heuristic (below pinch)
Maximize loads to tick o streams
to keep capital costs down
Chen CL
103
The Pinch Design Method
The Tick-O Heuristic (below pinch)
Then ll in the rest
Chen CL
104
The Pinch Design Method
The Tick-O Heuristic (below pinch)
Then ll in the rest
Chen CL
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
Chen CL
106
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
Chen CL
107
The Pinch Design Method
The Completed Design
Chen CL
108
The Pinch Design Method
Network Design Using Two Steam Levels
Chen CL
109
The Pinch Design Method
Network Design Using Two Steam Levels
Chen CL
110
The Pinch Design Method
Network Design Using Two Steam Levels
Chen CL
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
Chen CL
112
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
Chen CL
113
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
Chen CL
114
Stream Splitting: CP Inequality
Above Pinch: CPH CPC
Hot stream with larger CP values
Split into smaller parallel
hot streams
(opt ow rates ?)
Chen CL
115
Stream Splitting: CP Inequality
Below Pinch: CPH CPC
Cold stream with larger CP values
Split into smaller parallel
cold streams
(opt ow rates ?)
Chen CL
116
Stream-Splitting Algorithms
Above the Pinch
Chen CL
117
Stream-Splitting Algorithms
Below the Pinch
Chen CL
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
Chen CL
119
Pinch Analysis and Process Integration
Case Study
Crude Preheat Train
Chen CL
120
PI Case Study: Crude Preheat Train
Original Process
Chen CL
121
PI Case Study: Crude Preheat Train
Original Process
Chen CL
122
PI Case Study: Crude Preheat Train
Original Process
Chen CL
123
PI Case Study: Crude Preheat Train
Original Process
Chen CL
124
PI Case Study: Crude Preheat Train
Original Process
Chen CL
125
PI Case Study: Crude Preheat Train
Original Process
Chen CL
126
PI Case Study: Crude Preheat Train
Original Process
Chen CL
127
PI Case Study: Crude Preheat Train
Original Process
Chen CL
128
PI Case Study: Crude Preheat Train
Contractors Design
Chen CL
129
PI Case Study: Crude Preheat Train
Hot/Cold Streams
Chen CL
130
PI Case Study: Crude Preheat Train
Network Grid Diagram: Contractors Design
Chen CL
131
PI Case Study: Crude Preheat Train
Network Grid Diagram with Increased HEs
Chen CL
132
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
Chen CL
133
PI Case Study: Crude Preheat Train
Composite Curves and Grand composite Curve
Chen CL
134
PI Case Study: Crude Preheat Train
Network Grid Diagram: Contractors Design
Chen CL
135
PI Case Study: Crude Preheat Train
Contractors Network Showing Pinch Temperature
Chen CL
136
PI Case Study: Crude Preheat Train
Stream Grid Above The Pinch
Chen CL
137
PI Case Study: Crude Preheat Train
Complete MER Network Above The Pinch
Chen CL
138
PI Case Study: Crude Preheat Train
Stream Grid Below The Pinch
Chen CL
139
PI Case Study: Crude Preheat Train
Complete MER Network Below The Pinch
Chen CL
140
PI Case Study: Crude Preheat Train
Combined MER Network for Complete Process
Chen CL
141
PI Case Study: Crude Preheat Train
First Relaxation from MER Design
Chen CL
142
PI Case Study: Crude Preheat Train
Elimination of Four-way Stream Split
Chen CL
143
PI Case Study: Crude Preheat Train
Second Evolution of Network Design
Chen CL
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
Chen CL
145
PI Case Study: Crude Preheat Train
Original Process
Chen CL
146
PI Case Study: Crude Preheat Train
Contractors Design
Chen CL
147
PI Case Study: Crude Preheat Train
Final Selected Design
Chen CL
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).
Chen CL
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.
