- •1.1 What this chapter contains
- •1.2 What is Pinch Technology?
- •1.3 From Flowsheet to Pinch Data
- •1.3.1 Data Extraction Flowsheet
- •Thermal Data
- •1.4 Energy Targets
- •1.4.1 Construction of Composite Curves
- •1.4.2 Determining the Energy Targets
- •1.4.4 The Pinch Principle
- •1.5 Targeting for Multiple Utilities
- •1.5.1 The Grand Composite Curve
- •1.5.2 Multiple Utility Targeting with the Grand Composite Curve
- •1.6 Exergy Analysis
- •1.6.1 Carnot factor calculations
- •1.6.2 Constructing an exergy balance
- •1.7 Capital - Energy Trade-offs
- •1.7.1 New Designs
- •Setting Area Targets
- •Setting Minimum Number of Units Target
- •Determining the Capital Cost Target
- •1.7.2 Retrofit
- •Retrofit Targeting based on Capital-energy trade-off
- •Maintaining Area Efficiency
- •Payback
- •Retrofit targeting based on DTmin - Energy curves
- •DTmin Calculation in PinchExpress and PROCESS
- •Retrofit targeting based on experience DTmin values
- •Typical DTmin values for various types of processes
- •Typical DTmin values used for matching utility levels against process streams
- •Typical DTmin values used in retrofit targeting of various refinery processes
- •1.8 Process Modifications
- •1.8.1 The plus-minus principle for process modifications
- •1.8.2 Distillation Columns
- •Stand-alone column modifications
- •Column integration
- •1.9 Placement of Heat Engines and Heat Pumps
- •1.9.1 Appropriate integration of heat engines
- •Identifying opportunities for heat engine placement
- •1.9.2 Appropriate integration of heat pumps
- •Identifying opportunities for heat pump placement
- •1.10.1 The Difference Between Streams and Branches
- •1.10.2 The Grid Diagram for heat exchanger network representation
- •1.10.4 The New Design Method
- •Design Above The Pinch
- •Design Below The Pinch
- •Completed Minimum Energy Requirement Design
- •Stream splitting in network design
- •Network evolution: Heat load loops and heat load paths
- •Network design for multiple utilities
- •Summary: New heat exchanger network design
- •1.10.5 Heat Exchanger Network Design for Retrofits
- •Pinch Design Method with maximum re-use of existing exchangers
- •Correcting Cross-Pinch Exchangers
- •Use cross-pinch analysis to find a promising project in the current network
- •Use the Grid Diagram to design the project
- •Other steps
- •Analysis of Exchanger Paths
- •Retrofit example
- •1.11.1 Do not carry over features of the existing solution
- •1.11.2 Do not mix streams at different temperatures
- •1.11.3 Extract at effective temperatures
- •1.11.4 Extract streams on the safe side
- •1.11.5 Do not extract true utility streams
- •1.11.6 Identify soft data
- •1.12.1 Total site data extraction
- •Constructing Total Site Profiles
- •Adding steam users not accounted in process stream data
- •1.12.2 Total site analysis
- •Setting total site targets
- •Case study - Total site analysis
- •1.12.3 Selection of options: Total Site Road Map
- •Summary: Total Site Improvement
- •1.15 Index
12 |
Pinch Technology |
Chapter 1 |
H = Stream enthalpy
This is equivalent to calculating the area between the stream and the ambient temperature line, on a Carnot Factor vs. Enthalpy diagram. The exergy curves therefore provide a clear visual representation of where exergy is lost in the process and utility system.
For a stream which does not have a constant temperature the exergy value is calculated from:
Ex |
=H |
1 - T |
ln(T / T ) |
|
t s |
||||
( T - T ) |
||||
stream |
|
o |
||
|
|
|
t s |
where Ts and Tt are the stream source and target temperatures, respectively.
This is still equivalent to calculating the area between the stream and the ambient temperature line. However, the equation is now non-linear because a non-constant temperature stream actually appears slightly bent on the exergy curves. This is an obvious result of the non-linear relationship between Carnot Factor and stream temperature.
1.6.2 Constructing an exergy balance
The exergy equations can be used to construct an exergy balance around the process or site being analysed. In interpreting this balance the following table may prove useful:
Stream |
Removes Exergy |
Supplies Exergy |
Hot process stream above ambient |
|
Yes |
Hot process stream below ambient |
Yes |
|
Cold process stream above ambient |
Yes |
|
Cold process stream below ambient |
|
Yes |
Hot utility stream above ambient |
Yes |
|
Hot utility stream below ambient |
|
Yes |
Cold utility stream above ambient |
|
Yes |
Cold utility stream below ambient |
Yes |
|
1.7 Capital - Energy Trade-offs
The best design for an energy efficient heat exchange network will often result in a trade off between the equipment and operating costs. This is dependent on the choice of the DTmin for the process. The lower the DTmin chosen, the lower the energy costs, but conversely the higher the heat exchanger capital costs, as lower temperature driving forces in the network will result in the need for greater area. A large DTmin, on the other hand, will mean increased energy costs as there will be less overall heat recovery, but the required capital costs will be less. The trade-off is further complicated in a retrofit situation, where a capital investment has already been made. This section explains a rational approach to the complex task of capitalenergy trade-offs.