PROCESS INTEGRATION AND UNIT OPERATIONS

INTRODUCTION TO
PINCH TECHNOLOGY

Fotis Spyropoulos
F. Spyropoulos@bham.ac.uk
 STRUCTURE OF LECTURES

➥ Four 4-hour lecture sessions on Pinch

Technology.
➥ Each lecture session will consist of an
overview on theory with a few examples,
➥ followed by a tutorial.
➥ One compulsory exam question (more than
one parts) is set by myself and it will be
relating to material covered in the lectures/
tutorials.
 STRUCTURE OF LECTURES

➥ Your handouts have all aspects of the theory

covered in each lecture – but they should not be
your only source for revision.
➥ The theory part of each lecture session is
segmented – the key elements from each
segment will be summarised.
➥ These key elements
summaries are NOT provided
– you will be prompted to
take your own notes.

 STRUCTURE OF LECTURES

➥ Your handouts have all aspects of the theory

covered in each lecture – but they should not be
your only source for revision.
➥ The theory part of each lecture session is
segmented – the key elements from each
segment will be summarised.
➥ These key elements
summaries are NOT provided
– you will be prompted to
take your own notes.

PROCESS INTEGRATION AND UNIT OPERATIONS

PINCH TECHNOLOGY

PROCESS & HEAT
INTEGRATION
 PROCESS INTEGRATION

➥ Process integration is concerned

with process and product
development.

➥ The emphasis is on sustainability

including operability and economic
aspects.
 HEAT INTEGRATION – WHY?

➥ Reduce utility cost

➥ Improve energy efficiency

➥ Proper trade-off between capital

invested and operating cost of the
plant should be achieved
 HEAT INTEGRATION – WHY?

The main Objective is to design a network that meets

an economic criterion such as minimum total
annualized cost.

 
 CAPITAL OPERATING
 Operating Cost
COST COST

  umps &
P
compressors
REDUCTION TO ENERGY USE & COMPLEXITY
 REDUCTION TO ENERGY USE & COMPLEXITY
Flowsheet for the front end of a
specialty chemicals process
Traditional design
 REDUCTION TO ENERGY USE & COMPLEXITY
Flowsheet for the front end of a
specialty chemicals process
Traditional design

ΜΜ

H = 1722kW
C = 654kW
 REDUCTION TO ENERGY USE & COMPLEXITY
Flowsheet for the front end of a
specialty chemicals process
Traditional design

ΜΜ

H = 1722kW
6 units
C = 654kW
 REDUCTION TO ENERGY USE & COMPLEXITY
Flowsheet for the front end of a
specialty chemicals process

Pinch Analysi design

Traditional design

ΜΜ

H = 1722kW
6 units
C = 654kW
 REDUCTION TO ENERGY USE & COMPLEXITY
Flowsheet for the front end of a
specialty chemicals process

Pinch Analysi design

Traditional design

ΜΜ

ΜΜ
H = 1722kW H = 1068kW
6 units
C = 654kW C = 0kW
 REDUCTION TO ENERGY USE & COMPLEXITY
Flowsheet for the front end of a
specialty chemicals process

Pinch Analysi design

Traditional design

ΜΜ

ΜΜ
H = 1722kW H = 1068kW
6 units 4 units
C = 654kW C = 0kW
 REDUCTION TO ENERGY USE & COMPLEXITY
Flowsheet for the front end of a
specialty chemicals process

Pinch Analysi design

Traditional design

ΜΜ

ΜΜ
H = 1722kW H = 1068kW
6 units 4 units
C = 654kW C = 0kW
PROCESS INTEGRATION AND UNIT OPERATIONS

PINCH TECHNOLOGY
PART 1
PINCH TECHNOLOGY
vs TRADITIONAL DESIGN
PINCH TECHNOLOGY VS TRADITIONAL DESIGN
Energy Consumption

6.0

5.0

4.0

3.0

2.0
1.0

0
Successive plants
PINCH TECHNOLOGY VS TRADITIONAL DESIGN
Designs based on
traditional process design
Energy Consumption

6.0

5.0

4.0

3.0

2.0
1.0

0
Last Successive plants
process
PINCH TECHNOLOGY VS TRADITIONAL DESIGN
Designs based on
traditional process design
Energy Consumption

6.0

5.0

4.0

3.0

2.0
1.0

0
Last Successive plants
process
PINCH TECHNOLOGY VS TRADITIONAL DESIGN
Designs based on
traditional process design
Energy Consumption

6.0

5.0

4.0

3.0

2.0
1.0

0
Last Successive plants
process
PINCH TECHNOLOGY VS TRADITIONAL DESIGN
Designs based on
traditional process design
Energy Consumption

6.0

5.0

4.0

3.0

2.0
1.0

0
Last Successive plants
process Exiting
process
PINCH TECHNOLOGY VS TRADITIONAL DESIGN
Designs based on
traditional process design
Energy Consumption

6.0

5.0

4.0

3.0

2.0
1.0

0
Last New Successive plants
process Exiting process
process
PINCH TECHNOLOGY VS TRADITIONAL DESIGN
Designs based on
traditional process design
Energy Consumption

6.0

5.0

4.0

3.0
Learning Curve
2.0
1.0

0
Last New Successive plants
process Exiting process
process
PINCH TECHNOLOGY VS TRADITIONAL DESIGN
Designs based on
traditional process design
Energy Consumption

6.0

5.0

4.0

3.0
Learning Curve
2.0
1.0
Minimum energy
consumption
0
Last New Successive plants
process Exiting process
process
PINCH TECHNOLOGY VS TRADITIONAL DESIGN
Designs based on
traditional process design
Energy Consumption

6.0 Design following

Pinch analysis
5.0

4.0

3.0
Learning Curve
2.0
1.0
Minimum energy
consumption
0
Last New Successive plants
process Exiting process
process
PINCH TECHNOLOGY VS TRADITIONAL DESIGN
Designs based on
traditional process design
Energy Consumption

6.0 Design following

Pinch analysis
5.0

4.0

3.0
Learning Curve
2.0
1.0
Minimum energy
consumption
0
Last New Successive plants
process Exiting process
process
ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
important if energy costs are
high and capital costs are low?
 ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
150° 150° 150°
important if energy costs are
high and capital costs are low?

ç Consider this network
300° 200°

300° 200°

300° 200°

50° 50° 50°

 ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
150° 150° 150°
important if energy costs are
high and capital costs are low?

ç  Consider this network
300° 200°
➥ Which network design
would seem appropriate
300° 200°
when energy is cheap and
capital expensive?
300° 200°

50° 50° 50°

 ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
150° 150° 150°
Steam important if energy costs are
Cooling
high and capital costs are low?
H H H water
ç  Consider this network
300° 200°
C ➥ Which network design
would seem appropriate
300° 200°
C when energy is cheap and
H

capital expensive?
300° 200°
C

50° 50° 50°

Outline heat exchanger network for

“minimum capital cost”
 ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
150° 150° 150°
Steam important if energy costs are
Cooling
high and capital costs are low?
H H H water
ç  Consider this network
300° 200°
C ➥ Which network design
would seem appropriate
300° 200°
C when energy is cheap and
H

capital expensive?
300° 200°
C
➥ There is no process heat
recovery – only utility
50° 50° 50° usage.

Outline heat exchanger network for

“minimum capital cost”
 ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
150° 150° 150°
important if energy costs are
high and capital costs are low?

ç Consider this network
300° 200°

300° 200°

300° 200°

50° 50° 50°

 ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
150° 150° 150°
important if energy costs are
high and capital costs are low?

ç  Consider this network
300° 200°
➥ Which network design
would seem appropriate
300° 200°
when energy is expensive?

300° 200°

50° 50° 50°

 ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
150° 150° 150°
important if energy costs are
high and capital costs are low?

ç  Consider this network
300° 200°
➥ Which network design
would seem appropriate
300° 200°
when energy is expensive?

300° 200°

50° 50° 50°

Outline network for

“minimum energy cost”
 ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
150° 150° 150°
Steam important if energy costs are
Cooling
high and capital costs are low?
water
ç  Consider this network
300° 200°
➥ Which network design
would seem appropriate
300° 200°
when energy is expensive?

300° 200° ➥ There is as much process

heat recovery as is possible
in preference to utility
50° 50° 50° usage.

Outline network for

“minimum energy cost”
ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
important if energy costs are
high and capital costs are low?

 ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
150° 150° 150°
Steam important if energy costs are
Cooling
high and capital costs are low?
H H H water
Outline heat exchanger network
300° 200° for “minimum capital cost”
C

300° 200°
C
H

300° 200°
C

50° 50° 50°

 ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
150° 150° 150°
Steam important if energy costs are
Cooling
high and capital costs are low?
H water
Outline heat exchanger network
300° 200° for “minimum capital cost”

300° 200°
H

300° 200°

50° 50° 50°

 ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
150° 150° 150°
Steam important if energy costs are
Cooling
high and capital costs are low?
H water
Outline heat exchanger network
300° 200° for “minimum capital cost”
CP=1.0
➥  Assume a uniform heat
300° 200° transfer coefficient and
H

CP=1.0 sensible steam and cooling

300° 200° water temperatures.
CP=1.0

50° 50° 50°

 ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
150° 150° 150°
Steam important if energy costs are
Cooling
high and capital costs are low?
H water
Outline heat exchanger network
300° 200° for “minimum capital cost”
CP=1.0
➥  Assume a uniform heat
300° 200° transfer coefficient and
H

CP=1.0 sensible steam and cooling

300° 200° water temperatures.
CP=1.0

50° 50° 50°

CP=1.0 CP=1.0 CP=1.0
 ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
150° 150° 150°
Steam important if energy costs are
Cooling
high and capital costs are low?
100 100
H 100 water
Outline heat exchanger network
300° 200° for “minimum capital cost”
100
CP=1.0
➥  Assume a uniform heat
300° 200° transfer coefficient and
100
H

CP=1.0 sensible steam and cooling

300° 200° water temperatures.
100
CP=1.0

50° 50° 50°

CP=1.0 CP=1.0 CP=1.0
 ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
150° 150° 150°
Steam important if energy costs are
Cooling
high and capital costs are low?
100 100
H 100 water
Outline heat exchanger network
300° 200° for “minimum capital cost”
100
CP=1.0
➥  Assume a uniform heat
300° 200° transfer coefficient and
100
H

CP=1.0 sensible steam and cooling

300° 200° water temperatures.
100
CP=1.0
➥  The heat transfer area for the
50° 50° 50° low cost utility (minimum
CP=1.0 CP=1.0 CP=1.0 capital cost) design will be:

Σ(Area) = 204
 ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
150° 150° 150°
important if energy costs are
high and capital costs are low?

Outline heat exchanger network
300° 200° for “minimum energy cost”

300° 200°

300° 200°

50° 50° 50°

 ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
150° 150° 150°
important if energy costs are
high and capital costs are low?

Outline heat exchanger network
CP=1.0
300° 200° for “minimum energy cost”

CP=1.0
➥  Again, assume a uniform heat
300° 200° transfer coefficient.
CP=1.0
300° 200°

50° 50° 50°

CP=1.0 CP=1.0 CP=1.0
 ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
150° 150° 150°
important if energy costs are
high and capital costs are low?

Outline heat exchanger network
CP=1.0
300° 200° for “minimum energy cost”
100
CP=1.0
➥  Again, assume a uniform heat
300° 200° transfer coefficient.
100
CP=1.0 ➥  Design a simpler network
300° 200° which still achieves maximum
100
energy recovery.
50° 50° 50°
CP=1.0 CP=1.0 CP=1.0

 ENERGY RECOVERY & CAPITAL & ENERGY COSTS
Is energy recovery only
150° 150° 150°
important if energy costs are
high and capital costs are low?

Outline heat exchanger network
CP=1.0
300° 200° for “minimum energy cost”
100
CP=1.0
➥  Again, assume a uniform heat
300° 200° transfer coefficient.
100
CP=1.0 ➥  Design a simpler network
300° 200° which still achieves maximum
100
energy recovery.
50° 50° 50° ➥  The heat transfer area for the
CP=1.0 CP=1.0 CP=1.0 high cost utility (minimum
energy cost) design will be:

Σ(Area) = 133
ENERGY RECOVERY & CAPITAL & ENERGY COSTS
ENERGY RECOVERY & CAPITAL & ENERGY COSTS
ENERGY RECOVERY & CAPITAL & ENERGY COSTS

Σ(Area) = 204
ENERGY RECOVERY & CAPITAL & ENERGY COSTS

Σ(Area) = 133 Σ(Area) = 204

ENERGY RECOVERY & CAPITAL & ENERGY COSTS

Σ(Area) = 133 Σ(Area) = 204

➥ The “network for
minimum capital cost”
turns out to have the
higher total heat
transfer area.
ENERGY RECOVERY & CAPITAL & ENERGY COSTS

Σ(Area) = 133 Σ(Area) = 204

➥ The “network for
minimum capital cost”
turns out to have the
higher total heat
transfer area.

➥ As such the “network

for minimum capital
cost” is more expensive
in capital cost as well as
operating (energy) cost!
PROCESS INTEGRATION AND UNIT OPERATIONS

PINCH TECHNOLOGY

BASIC CONCEPTS
OF HEAT EXCHANGE
 BASIC CONCEPTS OF HEAT EXCHANGE
Consider the simple process shown below.
➥ Liquid, supplied to a reactor, needs to be heated from
20°C to the operating temperature of the reactor (200°C).
➥ Conversely, the hot liquid chemical reaction product
(150°C) needs to be cooled down to 50°C.

20°
Feed 200°
REACTOR
50° 150°
Product
Simple process flowsheet
 BASIC CONCEPTS OF HEAT EXCHANGE
➥ Any flow which requires to be heated or cooled, but does
not change in composition, is defined as a stream; the
reaction process is not a stream.

20°
Feed 200°
REACTOR
50° 150°
Product
Simple process flowsheet
 BASIC CONCEPTS OF HEAT EXCHANGE
➥ Any flow which requires to be heated or cooled, but does
not change in composition, is defined as a stream; the
reaction process is not a stream.
➥ The feed (being heated up) is a cold stream.

20°
Feed 200°
REACTOR
50° 150°
Product
Simple process flowsheet
 BASIC CONCEPTS OF HEAT EXCHANGE
➥ Any flow which requires to be heated or cooled, but does
not change in composition, is defined as a stream; the
reaction process is not a stream.
➥ The feed (being heated up) is a cold stream.
➥ The hot product (being cooled down) is a hot stream.

20°
Feed 200°
REACTOR
50° 150°
Product
Simple process flowsheet
 BASIC CONCEPTS OF HEAT EXCHANGE
Back to the simple chemical process

20°
Feed 200°
REACTOR
50° 150°
Product
Simple process flowsheet
 BASIC CONCEPTS OF HEAT EXCHANGE
Back to the simple chemical process
➥ To perform the heating, a steam heater could be placed on
the cold stream, and

HEATER
20° H
Feed 200°
REACTOR
50° 150°
Product
Simple process flowsheet
 BASIC CONCEPTS OF HEAT EXCHANGE
Back to the simple chemical process
➥ To perform the heating, a steam heater could be placed on
the cold stream, and
➥ to carry out the cooling, a water cooler could be placed on
the hot stream.

HEATER
20° H
Feed 200°
REACTOR
COOLER
50° 150°
C
Product
Simple process flowsheet
 BASIC CONCEPTS OF HEAT EXCHANGE
The heat content H of a stream (kW) is frequently called its
enthalpy; not the thermodynamic term!
Differential heat flow dQ , when added to a process stream,
will increase its enthalpy (H ) by {CP dT}, where:
➥ CP : heat capacity flowrate (kW/K)
➥ dT : differential temperature change
HEATER
20° H
Feed 200°
REACTOR
COOLER
50° 150°
C
Product
Simple process flowsheet
 BASIC CONCEPTS OF HEAT EXCHANGE
Hence, with CP assumed constant, for a stream requiring heating
(“cold” stream) from a “supply temperature” (TS ) to a “target
temperature” (TT ), the total heat added will be equal to the stream
enthalpy change, i.e.:
TT
Q= ∫ CP dT = CP (T T − TS ) = ΔH
TS

HEATER
20° H
Feed 200°
REACTOR
COOLER
50° 150°
C
Product
Simple process flowsheet
 BASIC CONCEPTS OF HEAT EXCHANGE
Therefore, for the 2 streams of our simple chemical process:

Heat Capacity flow Initial (supply) Final (target) Heat Load,

rate, CP (kW/°C) Temp., TS (°C) Temp., TT (°C) H (kW)
Cold stream 1.0 20 200 -180
Hot stream 1.8 150 50 +180

HEATER
20° H
Feed 200°
REACTOR
COOLER
50° 150°
C
Product
Simple process flowsheet
 BASIC CONCEPTS OF HEAT EXCHANGE
Therefore, for the 2 streams of our simple chemical process:

Heat Capacity flow Initial (supply) Final (target) Heat Load,

rate, CP (kW/°C) Temp., TS (°C) Temp., TT (°C) H (kW)
Cold stream 1.0 20 200 -180
Hot stream 1.8 150 50 +180

20° HEATER

H
We
Feed will need to supply 180 200° kW of steam
REACTOR
heating and 180 kW
COOLER of water cooling to
150°
operate the process.
50° C

Product
Simple process flowsheet
 BASIC CONCEPTS OF HEAT EXCHANGE
Can we reduce energy consumption?

HEATER
20° H
Feed 200°
REACTOR
COOLER
50° 150°
C
Product
Simple process flowsheet
 BASIC CONCEPTS OF HEAT EXCHANGE
Can we reduce energy consumption?

Yes; if we can recover some heat from the hot stream and
use it to heat the cold stream in a heat exchanger;

20°
HEAT
Feed
200°
REACTOR

50° EXCHANGER 150°

Product
Simple process flowsheet with heat exchanger
 BASIC CONCEPTS OF HEAT EXCHANGE
Can we reduce energy consumption?

Yes; if we can recover some heat from the hot stream and
use it to heat the cold stream in a heat exchanger; we will
then need less steam and water to satisfy the remaining
duties.

20° H
HEAT
Feed
200°
REACTOR

50° EXCHANGER 150°

C
Product
Simple process flowsheet with heat exchanger
 BASIC CONCEPTS OF HEAT EXCHANGE
Can we recover all 180 kW in the hot stream to heat the
cold stream?

20° H
HEAT
Feed
200°
REACTOR

50° EXCHANGER 150°

C
Product
Simple process flowsheet with heat exchanger
 BASIC CONCEPTS OF HEAT EXCHANGE
Can we recover all 180 kW in the hot stream to heat the
cold stream?
No; we can’t use a hot stream at 150°C to heat a cold
stream at 200°C!

20° H
HEAT
Feed
200°
REACTOR

50° EXCHANGER 150°

C
Product
Simple process flowsheet with heat exchanger
 BASIC CONCEPTS OF HEAT EXCHANGE
How much heat can we actually recover?

20° H
HEAT
Feed
200°
REACTOR

50° EXCHANGER 150°

C
Product
Simple process flowsheet with heat exchanger
 BASIC CONCEPTS OF HEAT EXCHANGE
How much heat can we actually recover?

How big should the exchanger be?

20° H
HEAT
Feed
200°
REACTOR

50° EXCHANGER 150°

C
Product
Simple process flowsheet with heat exchanger
 BASIC CONCEPTS OF HEAT EXCHANGE
How much heat can we actually recover?

How big should the exchanger be?

What will be the temperatures around it?

20° H
HEAT
Feed
200°
REACTOR

50° EXCHANGER 150°

C
Product
Simple process flowsheet with heat exchanger
 BASIC CONCEPTS OF HEAT EXCHANGE
Much of this can be determined if we establish ‘how
close’, in terms of temperatures, our cold and hot streams
can be.

This is termed as the process/design’s ΔTmin

requirements.

20° H
HEAT
Feed
200°
REACTOR

50° EXCHANGER 150°

C
Product
Simple process flowsheet with heat exchanger
PROCESS INTEGRATION AND UNIT OPERATIONS

PINCH TECHNOLOGY

CHOOSING ΔT : MIN

SUPERTARGETING
 CHOOSING ΔT : SUPERTARGETING
MIN

In a heat transfer device, the surface area A

required for heat exchange is given by:





 CHOOSING ΔT : SUPERTARGETING
MIN

In a heat transfer device, the surface area A

required for heat exchange is given by:
Q
A=
U ⋅ ΔTLM


 CHOOSING ΔT : SUPERTARGETING
MIN

In a heat transfer device, the surface area A

required for heat exchange is given by:
Q
A=
U ⋅ ΔTLM

where, A is in m2, Q is the heat transferred in
the exchanger (kW), U is the overall heat
transfer coefficient (kW. m-2. K-1) and ΔTLM is
the log mean temperature difference (K).
 CHOOSING ΔT : SUPERTARGETING
MIN

Consider a heat exchanger (shell and tube),

operating counter-currently;
 CHOOSING ΔT : SUPERTARGETING
MIN

Consider a heat exchanger (shell and tube),

operating counter-currently;
 CHOOSING ΔT : SUPERTARGETING
MIN

Consider a heat exchanger (shell and tube),

operating counter-currently;
 CHOOSING ΔT : SUPERTARGETING
MIN

Consider a heat exchanger (shell and tube),

operating counter-currently;
 CHOOSING ΔT : SUPERTARGETING
MIN

Consider a heat exchanger (shell and tube),

operating counter-currently;
 CHOOSING ΔT : SUPERTARGETING
MIN

Consider a heat exchanger (shell and tube),

operating counter-currently;
 CHOOSING ΔT : SUPERTARGETING
MIN

Consider a heat exchanger (shell and tube),

operating counter-currently;
 CHOOSING ΔT : SUPERTARGETING
MIN

Consider a heat exchanger (shell and tube),

operating counter-currently;
 CHOOSING ΔT : SUPERTARGETING
MIN

Consider a heat exchanger (shell and tube),

operating counter-currently;
➥ the hot stream enters at TH1 and leaves at TH2, and

TH2 TH1
 CHOOSING ΔT : SUPERTARGETING
MIN

Consider a heat exchanger (shell and tube),

operating counter-currently;
➥ the hot stream enters at TH1 and leaves at TH2, and
➥ the cold stream enters at TC1 and exits at TC2, so

TH2 TH1

TC1 TC2
 CHOOSING ΔT : SUPERTARGETING
MIN

Consider a heat exchanger (shell and tube),

operating counter-currently;
➥ the hot stream enters at TH1 and leaves at TH2, and
➥ the cold stream enters at TC1 and exits at TC2, so
➥ TC1 and TH2 are at the “cold end” C and

TH2 TH1

TC1 TC2
 CHOOSING ΔT : SUPERTARGETING
MIN

Consider a heat exchanger (shell and tube),

operating counter-currently;
➥ the hot stream enters at TH1 and leaves at TH2, and
➥ the cold stream enters at TC1 and exits at TC2, so
➥ TC1 and TH2 are at the “cold end” C and
➥ TH1 and TC2 the “hot end” H of the exchanger.

TH2 TH1

TC1 TC2
 CHOOSING ΔT : SUPERTARGETING
MIN

Consider a heat exchanger (shell and tube),

operating counter-currently;

TH2 TH1

TC1 TC2
 CHOOSING ΔT : SUPERTARGETING
MIN

Consider a heat exchanger (shell and tube),

operating counter-currently; ΔTLM, in this case, is:

ΔTH − ΔTC TH1 − TC 2 − TH 2 + TC1

ΔTLM = =
ΔTH # TH1 − TC 2 &
ln ln % (
ΔTC $ TH 2 − TC1 '

TH2 TH1

TC1 TC2
 CHOOSING ΔT : SUPERTARGETING
MIN

➥  It can be shown that for ΔTmin approaching 0, so

will be ΔTLM .

TH2 TH1

TC1 TC2
 CHOOSING ΔT : SUPERTARGETING
MIN

➥  It can be shown that for ΔTmin approaching 0, so

will be ΔTLM .

➥  This means that the area

Q
required for heat exchange A=
(A) will be infinitely big. U ⋅ ΔTLM

TH2 TH1

TC1 TC2
 CHOOSING ΔT : SUPERTARGETING
MIN

Exchanger
 CHOOSING ΔT : SUPERTARGETING
MIN

Exchanger
➥  Exch. area
increases
asymptotically as
ΔTmin is reduced.
➥  Exch. cost
proportional to
exch. area.
 CHOOSING ΔT : SUPERTARGETING MIN

250
Exchanger
➥  Exch. area
increases 200
asymptotically as
ΔTmin is reduced.
➥  Exch. cost Area or Cost 150
proportional to
exch. area. 100

50

0
0 20 40 60 80 100 120 140
ΔTmin
 CHOOSING ΔT : SUPERTARGETING MIN

250
Exchanger
➥  Exch. area
increases 200
asymptotically as
ΔTmin is reduced.
➥  Exch. cost Area or Cost 150
proportional to
exch. area. 100

50

0
0 20 40 60 80 100 120 140
ΔTmin
 CHOOSING ΔT : SUPERTARGETING MIN

250
Exchanger

Utility 200

Area or Cost 150

100

50

0
0 20 40 60 80 100 120 140
ΔTmin
 CHOOSING ΔT : SUPERTARGETING MIN

250
Exchanger

Utility 200

➥  Use increases
linearly with ΔTmin.
Area or Cost 150
➥  Utility cost
proportional to
utility use. 100

50

0
0 20 40 60 80 100 120 140
ΔTmin
 CHOOSING ΔT : SUPERTARGETING MIN

250
Exchanger

Utility 200

➥  Use increases
linearly with ΔTmin.
Area or Cost 150
➥  Utility cost
proportional to
utility use. 100

50

0
0 20 40 60 80 100 120 140
ΔTmin
 CHOOSING ΔT : SUPERTARGETING MIN

250
Exchanger

Utility 200

Total Cost
Area or Cost 150

100

50

0
0 20 40 60 80 100 120 140
ΔTmin
 CHOOSING ΔT : SUPERTARGETING MIN

250
Exchanger

Utility 200

Total Cost
Area or Cost 150
➥  Includes utility,
exchanger, heater
and cooler costs. 100
➥  Optimum ΔTmin is
for minimum total 50
cost.

0
0 20 40 60 80 100 120 140
ΔTmin
 CHOOSING ΔT : SUPERTARGETING MIN

250
Exchanger

Utility 200

Total Cost
Area or Cost 150
➥  Includes utility,
exchanger, heater
and cooler costs. 100
➥  Optimum ΔTmin is
for minimum total 50
cost.

0
0 20 40 60 80 100 120 140
ΔTmin
 CHOOSING ΔT : SUPERTARGETING MIN

250
Exchanger

Utility 200

Total Cost
Area or Cost 150
➥  Includes utility,
exchanger, heater
and cooler costs. 100
➥  Optimum ΔTmin is
for minimum total 50
cost.
➥  In this case
optimum ΔTmin is 0
~15-20°C. 0 20 40 60 80 100 120 140
ΔTmin
 CHOOSING ΔT MIN

➥ Maximising heat recovery does not

always equate achieving maximum cost
savings.
 CHOOSING ΔT MIN

➥ Maximising heat recovery does not

always equate achieving maximum cost
savings.
➥ This would only minimise costs
associated to running/operating costs
(e.g. utilities).
 CHOOSING ΔT MIN

➥ Maximising heat recovery does not

always equate achieving maximum cost
savings.
➥ This would only minimise costs
associated to running/operating costs
(e.g. utilities).
➥ The choice for ΔTmin should also be
taking into consideration capital costs.
 CHOOSING ΔT MIN

Industrial Sector Typical ΔTmin

Oil Refining 20-40°C
Petrochemical 10-20°C
Chemical 10-20°C
Low Temperature 3-5°C
Processes
 PINCH TECHNOLOGY

➥ ΔTmin is a quantity that we know in

advance and utilise in the design of a Heat
Exchanger Network.
➥ Pinch is the Temperature within the Heat
Exchanger Network, at which our cold
and hot stream(s) exist at a ΔTmin.
➥ Hot stream should always be ΔTmin
degrees higher than the cold stream at
either side of any heat exchanger in our
design.
 PINCH TECHNOLOGY - OBJECTIVES

Given data on the hot and cold streams of

a process, you should be able to:
➥ Identify the pinch temperature
➥ Set Maximum Energy Recovery
targets
➥ Design a simple Heat Exchanger
Network (HEN) such that Minimum
Utilities or MER (Maximum Energy
Recovery) targets are met.
 COURSE RESOURCES

➥ ‘User Guide on Process Integration for

the Efficient Use of Energy’
published by the Institutions of
Chemical Engineers (IChemE),
➥ Pinch Technology Notes
➥ Lecture slides
PROCESS INTEGRATION AND UNIT OPERATIONS

INTRODUCTION TO
PINCH TECHNOLOGY

Fotis Spyropoulos
F. Spyropoulos@bham.ac.uk