Pinch Analysis of Heat Exchanger Network
Pinch Analysis of Heat Exchanger Network
Pinch Analysis of Heat Exchanger Network
analysis is that it determines the most appropriate set networks obtained from the pipe flow diagram (PFD)
of heat exchange stream matches. In doing so, are shown below.
minimizes energy loss, reduces the cost of hot and
cold utilities and can be used to determine the
minimum requirement for both hot and cold utilities
in a process and thus, enhance process integration
(Promvitak, 2001). Chemical plants have in the past
been designed using the traditional design techniques,
which involved mass and energy balances, heuristics
or rules of thumb, good engineering judgment and
creative ability of the designers. Such designs were
neither optimal in terms of energy consumption nor
in capital cost invested. A typical example of such
deficiency in design is the Nigerian refineries as
reported in the works of Anozie and Odejobi, (2007);
resulting in frequent breakdown, excessive energy
loss, minimum energy recovery, poor process
network dynamics and control.
476
Journal of Emerging Trends in Engineering and Applied Sciences (JETEAS) 3(3):475-484 (ISSN: 2141-7016)
Cold 154.767
207 122 56.0000 2.7637 11734.47
LDO 2
Cold
168 115 32.2333 2.7206 87.6939 4140.21
kerosene
Cold 171.845
164 150 72.4416 2.3722 2442.26
Residue 9
Crude
488.317
from 25 137 232.2889 2.1022 56299.86
7
Storage
Table 3: Problem Table for HEN – 3 little excess cold utility (energy) not utilized for
Specific Heat cooling.
Start/
Target Mass flow heat capacity Heat duty
Streams supply
temp rate (kg/s) capacity flow rate (kW)
temp
(kJ/kgo C) (kW/o C) The pinch location cuts across the end points of the
LDO
276 253 120.8333 3.0529 368.8919 13955.76 hot and cold composite curves, implying that there
PA
should be no external hot utility (like heater) in this
HVGO 241 222 122.7000 2.6971 330.9342 5814.9
network. Although there is no heater in the HEN-1 of
the CDU, the little excess cold utility revealed by the
Crude
from
curve still indicates a heat imbalance due to the
Pre- 202 353 212.9277 2.8158 599.5618 112809.06 absence of a hot utility (stream requiring heating) to
flash match the little excess cold utility.
drum
(Fuel
Oil)
353 350 108.6240 3.2362 351.5389 93038.40 In the Grand Composite Curve shown in figure 6, the
area to the right of the dotted/pinch line shows the
amount of heat energy efficiently utilized by the hot
Constructing the Composite Curves
and cold streams, while the area to the left indicates
This is a plot of the temperature-enthalpy profile of
the excess heat not utilized within the network. A
all streams in a network. The plot gives the minimum
targeting report of the HEN-1 pinch shows that HEN-
heating requirement (hot utility) for the cold streams 1 requires a minimum cold utility of 2421.0kW
and cooling requirement (cold utility) for the hot (external heat requirement) and minimum hot utility
streams, the amount of heat utilized between the of 0Kw (no heating requirement). The pinch location
process streams and the minimum temperature is at one far end of the grid diagram indicating
change that should exist between the hot and cold
improper stream matching. A typical grid diagram
streams (the pinch value). The area enclosed within
should contain a region above the pinch (LHS of
the cold and hot composite curves accounts for the
pinch location) and a region below the pinch (RHS of
potential process-to-process heat recovery (minimum
pinch location) separated by a pinch location point,
energy requirements) while the area not enclosed at
the grid diagram of HEN-1 only contains a region
the extreme left is the excess cold utility been wasted
below the pinch. This implies that the HEN-1 of the
by the network. CDU of Port Harcourt refinery is not properly placed
on network grid diagram for design analysis using the
Representing the Heat Exchanger Network On A pinch analysis. The grid diagram also showed that no
Grid Diagram
heat exchanger crossed the pinch line, indicating all
Each heat exchanger in the network was represented
heat exchanger are properly placed.
as a grid. The process streams are drawn as horizontal
lines with hot streams drawn at the top of the grid
Analysis of Heat Exchanger Network-2
from left to right while cold streams are drawn at the
The composite and grand composite curves and grid
bottom from right to left. The stream numbers and diagram of the twelve (12) heat exchangers in HEN 2
heat capacities are shown on and at the end of the are shown in figure 8, figure 9 and figure 10
stream lines respectively. The diagram shows the heat
respectively. The right and left end of the composite
exchangers that violate the pinch rule (that cross the
curve shows that the hot and cold streams have
pinch). The heat exchangers are represented by
varying enthalpy, indicating excesses in both hot and
vertical lines linking a hot stream and a cold stream. cold utilities (energy) not utilized for heating and
Culprit heat exchangers are identified by an cooling, a heat imbalance between the streams and
additional bar attached to the vertical line. A
utilities, improper stream matching, inadequate and
targeting report is also generated showing heat duties inefficient process to process heat integration and
of all existing heat exchanger and cross pinch penalty utilization. Hence the streams in HEN-2 are not fully
(amount of heat energy not utilized) of culprit heat
utilizing all heat generated by the network. The pinch
exchangers.
location cuts in-between the end-points of the hot and
cold composite curves, implying that the HEN-2 is
RESULTS AND DISCUSSIONS
properly represented on the grid diagram for analysis.
Analysis of Heat Exchanger Network-1
Once again, the heat imbalance in the network is
The composite and grand composite curves and grid
clearly evident as the curve reveals little excess hot
diagram for the seven (7) heat exchangers in HEN 1 utility below the pinch and excess cold utility above
are shown in figure 5, figure 6 and figure 7 the pinch.
respectively. The right end of the composite curves
show that the hot and cold streams have the same
The Grand Composite Curve in figure 9 shows an
enthalpy indicating proper stream matching, adequate
irregular curve with scattered enclosures. The
and efficient process to process heat integration and
summation of areas to the right of the dotted lines
utilization. Therefore there is zero excess hot utility.
gives the amount of heat energy efficiently utilized
However, the left end of the curve shows that there is
by the hot and cold streams, while the areas to the left
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Journal of Emerging Trends in Engineering and Applied Sciences (JETEAS) 3(3):475-484 (ISSN: 2141-7016)
collectively indicate the excess heat not utilized pinch effect is observed as there are 8 heat
within the network. Comparing, this shows a exchangers violating the pinch rule and resulting in
relatively fair process-to-process stream matching in pinch penalty of -2817.20kW, these culprit heat
the network. In addition, the targeting report reveals exchangers are clearly identified by the vertical lines
that there is a minimum hot utility of 2817.20kW and attached to horizontal bars running (crossing) from
minimum cold utility of -2817.20kW. Although the left to right of the pinch location.
network grid diagram on figure 10 shows a good
representation and clarity of pinch location, a cross
COMPOSITE CURVES (Real T, No Utils)
Case: HEN_1
Heat Imbalance DTMIN =30.00
350.0
250.0
HOT HDO
TEMPER ATUR E C
COLD LDO
200.0 HOT HDO
COLD R
COLD KER
COLD LDO
COLD KER HOT HDO
TOP PA
150.0 COLD LDO
HOT HDO
COLD KER
TOP PA CRUDE ST
Pinch
100.0
Location
TOP PA
50.0
CRUDE ST
0.0
0.0 10.0 20.0 30.0 40.0 50.0 60.0
ENTHALPY X10 3 kW
Case: HEN_1
Heat Imbalance DTMIN =30.00
300.0
HOT HDO
250.0
200.0
TEMPERATU RE C
COLD LDO
HOT HDO
150.0
COLD R
COLD KER
CRUDE ST
COLD LDO
HOT HDO
100.0
CRUDE ST
TOP PA
50.0
CRUDE ST
0.0
0.0 2.0 4.0 6.0 8.0 10.0 12.0
COLD
ENTHALPY X10 3 kW
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Journal of Emerging Trends in Engineering and Applied Sciences (JETEAS) 3(3):475-484 (ISSN: 2141-7016)
308.0
148.0
(hot )
142.0
(pinch location)
Case: HEN_2
He at Imbala nce DTMIN =3 0.00
2 60.0
HOT LDO
2 40.0
Hot stream HOT KERO
T =24 0.9
Q =4 4.5
HOT L DO
MILD R
HOT KERO
HOT LDO
2 20.0 H.KER PA
MIL D R
TEMPERATURE C
HOT KERO
H.KER PA
MILD R
2 00.0
CRUDE DE
HOT KERO
H.KER PA
MILD R
1 80.0
H.KER PA Pinch
MIL D R Loca tion
1 60.0 T =1 60.2
Q =1.7
1 40.0
CRUDE DE
Cold stream
1 20.0
0 .0 10 .0 20 .0 30 .0 4 0.0 50.0
ENTHALPY X10 3 kW
Ca se: HEN_2
Hea t Imba lance DTMIN =30.00
260 .0
240 .0
HOT L DO
220 .0
TEMPERATURE C
HOT KERO
HOT LDO
CRUDE DE
HOT KERO
HOT LDO
CRUDE DE
MIL D R
200 .0
HOT KERO
HOT L DO
H.KER PA
CRUDE DE
MILD R
180 .0
HOT KERO
160 .0 H.KER PA
CRUDE DE
MILD R
H.KER PA
CRUDE DE
140 .0
0 .0 1.0 2.0 3.0 4.0 5.0 6.0 7.0
ENTHALPY X10 3 kW
219.0
168.0
207.0
184.0 155.0
204.0 164.0
CRUDE DE 202.0 202.0 202.0 198.0 189.0 168.0 158.0 141.0 129.0
189.0
U:4 U:4
QS:2817.2 QS:2817.2
Figure 10: Grid Representation of HEN-2 report further shows a minimum hot utility of
96098.90kW and minimum cold utility of
Analysis of Heat Exchanger Network-3 3060.50kW.
The composite and grand composite curves and grid
diagram of the four (4) heat exchangers in HEN 3 are Figure 13 shows the pinch location positioned at the
shown in figure 11, figure 12 and figure 13 extreme right on the grid diagram indicating
respectively. The right end of the composite curve improper stream matching and grid diagram of HEN-
shows a large hot utility (a large cold stream 3 only contains a region above the pinch (LHS of
requiring heating) while the left end shows very little pinch location). This implies that the HEN-3 of the
cold utility (very little hot stream require cooling). CDU of Port Harcourt refinery is not properly placed
This indicates a large heat imbalance between the on network grid diagram for design analysis. A cross
streams and utilities, improper stream matching, pinch effect was also observed as there are 2 out of 4
inadequate and inefficient process to process heat heat exchangers violating the pinch rule(not properly
integration and utilization. There is also very little placed) resulting in a pinch penalty of -3060.47kW.
potential for process-to-process heat recovery as These culprit heat exchangers are clearly identified
indicated by the small area enclosed by the cold and by the vertical lines attached to horizontal bars
hot composite curves. These results are further running (crossing) from left to right of the pinch
confirmed as the HEN-3 of the CDU contains more location.
cold process streams requiring heating. The targeting
COMPOSITE CURVES (Real T, No Utils)
Case: HEN_3
He at Imbalance DTMIN =30.00
360.0
Pinch T =352.6
Locatio n Q =115.5
CRUDE PL
320.0
TEMPERATURE C
T =2 75.3
280.0 Q =19.5
T =276.6
LDO PA Q =54.9
Hot stream
HVG O
LDO PA
240.0
HVGO
CRUDE PL
Cold stream
200.0
0.0 20.0 40.0 60.0 80.0 100.0 120.0
ENTHALPY X10 3 kW
T =365.6
Q =94.2
360.0
T E M P E R A TU R E C
320.0
CRUDE PL
280.0
240.0 CRUDE PL
LDO PA
CRUDE PL
HVGO
LDO PA
200.0
0.0 20.0 40.0 60.0 80.0 100.0
ENTHALPY X10 3 kW
232.0
235.0
(hot)
Pinch
Location
CRUDE PL 353.0 237.0 237.0 212.0 202.0
202.0
U:2 U:0
QS:96098.9 QS:3060.5
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Journal of Emerging Trends in Engineering and Applied Sciences (JETEAS) 3(3):475-484 (ISSN: 2141-7016)
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Journal of Emerging Trends in Engineering and Applied Sciences (JETEAS) 3(3):475-484 (ISSN: 2141-7016)
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