Pinch analysis in the field of paper mills, waste water mangement, brewing etc.

1. JINCY JACOB
1BM12BT013
GUIDE’S NAME: PRATHIBHA NARAYANAN

2. Pinch analysis is a methodology for minimizing
energy consumption of chemical processes by
calculating minimum energy required and
achieving them by optimizing heat recovery
systems, energy supply methods and process
operating conditions.
It is also known as process integration, heat
integration, energy integration or pinch
technology.

3. oPinch analysis is a rigorous, structured approach that may be used to
tackle a wide range of improvements related to process and site utility.
oThis includes opportunities such as reducing operating cost,improving
efficiency, and reducing and planning capital investment.
oMajor reasons for the success of pinch analysis are the simplicity of
the concepts behind the approach.
oIt analyzes a commodity, principally energy, hydrogen or water , in
terms of its quality and quality, recognizing the fact that the cost of
using that commodity will be a function of both.

4. oIn 1971, Ed Hohmann stated in his PhD that 'one can
compute the least amount of hot and cold utilities
required for a process without knowing the heat
exchanger network that could accomplish it. One also can
estimate the heat exchange area required'.
oPinch Analysis was originally developed by Bodo Linnhoff
and John Flower in 1978 at the University of Leeds.
oIn late 1977, Ph.D. student Bodo Linnhoff under the
supervision of Dr John Flower at the University of
Leeds showed the existence in many processes of a heat
integration bottleneck, ‘the pinch’, which laid the basis
for the technique, known today as pinch-analysis.

5. oWater pinch analysis (WPA) originates from the concept of heat pinch
analysis.
oWPA is a systematic technique for reducing water consumption and
wastewater generation through integration of water-using activities or
processes.
oWPA was first introduced by Wang and Smith.
oSince then, it has been widely used as a tool for water conservation in
industrial process plants.
oWater Pinch Analysis has recently been applied for urban/domestic
buildings.
oHydrogen pinch analysis (HPA) is a hydrogen management method that
originates from the concept of heat pinch analysis.
o HPA is a systematic technique for reducing hydrogen consumption and
hydrogen generation through integration of hydrogen-using activities or
processes in the petrochemical industry, petroleum refineries hydrogen
distribution networks and hydrogen purification.

6. a. Energy saving, and greenhouse gas emission
reduction
b. Optimization of batch processes
c. Optimization of hydrogen use
d. Reactor design and operation improvements
e. Minimization of water use and wastewater
production
f. Waste minimization
g. Investment cost reduction

7. a. Chemicals
b. Petrochemicals
c. Oil refining
d. Pulp & Paper
e. Food & Drink
f. Steel & Metallurgy

8. Combined( Hot and Cold) Composite Curve: Used to predict targets for
• Minimum energy required
• Minimum network area required
• Minimum number of exchanger units required
DTmin and Pinch Point: the DTmin value determines how closely the hot and cold
composite curve can be ‘pinched’ (or squeezed) without violating the Second Law of
Thermodynamics.
Grand Composite Curve: Used to select appropriate levels of utilities to meet over
all energy requirements.
Energy And Capital Cost Targeting: Used to calculate total annual cost of utilities
and capital cost of heat exchanger network
Pinch Temperature : The temperature at the point where the hot and cold
composites differ by the minimum temperature difference

10.  HeatIT - Version of Pinch Analysis software that runs in Excel - developed
by Pinchco, a consultancy company offering expert advice on energy related
matters.
 Pinchleni- Developed by Laboratoire d'Energétique Industrielle de l'Ecole
Polytechnique Fédérale de Lausanne, Switzerland
 Online Pinch Analysis Tool- Hosted by the College of Chemical Engineering
at the University of Illinois at Chicago
 Simulis Pinch - Tool from ProSim SA that can be used directly in Excel and
that is dedicated to the diagnosis and the energy integration of the
processes.
 Pinexo- Developed out of research at Chalmers Technical University,
Gothenburg Sweden

12.  p
o Technique is presented for integrating
hot and cold process streams in the
oleic acid production case study.
o Pinch analysis technique is employed
to target the minimum hot and cold
utility consumptions of the process.
An amount of 948.90 kWh of energy
has been recovered for the case
study.
o This represents the savings of 71.4%
and 62.5% for hot and cold utilities
respectively.
o It was also found that the minimum
energy requirement can be achieved
without the use of heat storage
system.Chew Yin Hoon, Dominic Foo Chwan Yee

13. o The problem faced at the paper plant,
was that large quantities of water were
being consumed by its paper machines,
therefore the aim of the research study
was to determine an effective approach
to reduce the specific water
consumption on these machines.
o A pinch analysis approach was selected
to give some insight to the problem.
o It has been identified that a fine
filtration system can replace all
regeneration equipment.
o Identified a potential reduction of fresh
water by 60 - 70 % on the paper
machines.T.N. Iswalal, C.A Buckley, I. Kerr Pollution
research group, University of KwaZulu-Natal,
South Africa

14. o This paper presents a methodology aimed at
improving the energy efficiency of a brewery
applying process integration techniques.
o Pinch Analysis targets the minimum heat
requirement of a process through the
graphical representation of the process
energy requirements, called composite
curves, and describes how it is possible to
achieve the determined energy targets with a
correctly designed network of heat
exchangers.
o The definition and the modeling of the
identified process units allows the
determination of the heat recovery potential
between process streams using Pinch
Analysis. The analysis of the process
composite curves enables a first identification
of the utilities that can be used to fulfill the
determined Minimum Energy Requirements.
Monika Dumbliauskaite , Helen Becker ,
Franc¸ois Marechal

15. o In this paper the process engineers seek to
"integrate“ the heating and cooling
requirements wherever possible. For
instance, if it is desired to cool a 160° F
stream. and to heat a 120°F steam, one
can use the "hot" stream to add heat to
the "cold" stream in an amount depending
on the capacitance rates.
o With the pitch analysis, the temperature
and capacitance rates of all "hot" streams
are combined into a single "hot
composite" plot.
o Likewise, the temperature and capacitance
rates of all "cold" streams are combined
into a single "cold composite."
o These two plots can then be overlaid to
accommodate a specified minimum
temperature difference for heat exchange
between the hot and cold streams. Once
this bas been due, the maximum possible
heat recovery is able to be determined.
S. Zem, J. Mitchell, D. R.einemann, S. Klein,
and D. Reindl Solar Energy Labomtory,
University ofWISOODSin - Madison

16.  A systematic procedure. It guarantees an optimum solution without relying on
luck or inspired guesses by the design engineer.
 A common denominator methodology. Based on fundamental thermodynamics,
pinch analysis applies to all processes and technologies, continuous and batch,
new and retrofit.
 Proven energy savings. Reductions of 15% or more in energy cost are typical,
even where processes have already been optimized by "conventional" methods.
 Automatic pollution prevention. Reduced CO2, SO2 & NO2 emissions are the
natural consequence of better energy efficiency.
 Lower cost debottlenecking. Pinch analysis shows us how to make better use of
existing equipment and systems, and thus minimizes new equipment
requirements in capacity upgrades.

17. PAPERS:
 THE PINCH-ANALYSIS AND OPTIMIZATION OF INDUSTRIAL FACILITIES : S.V. Zhulaev
 EVALUATING HEAT INTEGRATION SCHEME FOR BATCH PRODUCTION OF OLEICACID:
Chew Yin Hoon, Dominic Foo Chwan Yee
 APPLYING A WATER PINCH ANALYSIS TECHNIQUE TO REDUCE THE WATER
CONSUMPTION AT A PAPER MILL: T.N. Iswalal, C.A Buckley, I. Kerr
 PINCH ANALYSIS-BASED APPROACH TO CONCEPTUAL DESIGN OF INTERNALLY HEAT-
INTEGRATED DISTILLATION COLUMNS: M. Gadalla, Z. Olujic, L. Sun, A. DE RIJKE And P. J.
Jansens
 UTILITY OPTIMIZATION IN A BREWERY PROCESS BASED ON ENERGY INTEGRATION
METHODOLOGY: Monika Dumbliauskaite, Helen Becker, Franc¸ois Marechal
 PROCESS ENERGY EFFICIENCY IMPROVEMENT IN WISCONSIN CHEESE PLANTS: S. Zem, J.
Mitchell, D. R.einemann, S. Klein, and D. Reindl
BOOKS
PINCH ANALYSIS AN EFFECTIVE USE OF ENERGY,WATER AND HYDROGEN : 2013 EDITION
Linhoff, B., "Use Pinch Analysis to Knock Down Capital Costs and Emissions," Chemical
Enaineering Progre~ Vol. 90, No.8, pp. 32-57,