JINCY JACOB1BM12BT013

GUIDE’S NAME: PRATHIBHA NARAYANAN

PINCH ANALYSIS IN

BIOTECHNOLOGY

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.

INTRODUCTION

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.

o It 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.

PINCH ANALYSIS

o In 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.

o In 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.

HISTORY

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.

TYPES OF PINCH ANALYSIS

a. Energy saving, and greenhouse gas emission reduction

b. Optimization of batch processesc. Optimization of hydrogen used. Reactor design and operation improvementse. Minimization of water use and wastewater

productionf. Waste minimizationg. Investment cost reduction

Pinch Analysis techniques may be applied to address the following industrial issues:

a. Chemicalsb. Petrochemicalsc. Oil refiningd. Pulp & Papere. Food & Drinkf. Steel & Metallurgy

Used in the following industries:

Combined( Hot and Cold) Composite Curve: Used to predict targets for• Minimum energy required• Minimum network area required• Minimum number of exchanger units requiredDTmin 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

NOMENCLATURE USED IN PINCH ANALYSIS

GRAND COMPOSITE CURVE

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

SOFTWARES USED FOR PINCH ANALYSIS IN INDUSTRIES

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.

PAPER 1: Evaluating Heat Integration Scheme For Batch Production Of Oleic Acid

Chew Yin Hoon, Dominic Foo Chwan Yee

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.

PAPER 2:Applying a water pinch analysis technique to reduce the water consumption at a paper mill.

T.N. Iswalal, C.A Buckley, I. Kerr Pollution research group, University of KwaZulu-Natal, South Africa

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.

PAPER 3: Utility Optimization in a Brewery Process Based on Energy Integration Methodology

Monika Dumbliauskaite , Helen Becker , Franc¸ois Marechal

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.

oWith 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.

PAPER 4 : Process Energy Efficiency Improvement In Wisconsin Cheese Plants

S. Zem, J. Mitchell, D. R.einemann, S. Klein, and D. Reindl Solar Energy Labomtory, University ofWISOODSin - Madison

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.

CONCLUSIONPinch analysis has several advantages over "conventional" design approaches:

PAPERS: THE PINCH-ANALYSIS AND OPTIMIZATION OF INDUSTRIAL FACILITIES : S.V. Zhulaev EVALUATING HEAT INTEGRATION SCHEME FOR BATCH PRODUCTION OF OLEIC ACID: 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

BOOKSPINCH ANALYSIS AN EFFECTIVE USE OF ENERGY,WATER AND HYDROGEN : 2013 EDITIONLinhoff, B., "Use Pinch Analysis to Knock Down Capital Costs and Emissions," Chemical Enaineering Progre~ Vol. 90, No.8, pp. 32-57,

REFERENCES