Pinch Analysis for Energy and Carbon Footprint Reduction

Ian Kemp has over 30 years of experience in pinch analysis and process energy reduction, including consultancy, R&D, and technical writing. He was a principal technologist at AEA Technology, Harwell, and a scientific leader at GSK. He received the IChemE Junior Moulton Medal in 1989 for his paper on Batch Process Integration and the IChemE Brennan Medal in 2007 for the second edition of this book. His specialties include solids processing, particularly of pharmaceuticals, and drying processes, including spray drying, fluid bed drying and granulation, and dryer selection and troubleshooting, as well as energy reduction, sustainability, and pinch analysis. Dr. Jeng Shiun Lim is a researcher in Process Systems Engineering Center (PROSPECT) and Research Institute of Sustainable Environment (RISE). His specialties include energy management and energy planning for greenhouse gas emissions reduction and resource conservation and planning via systematic techniques (pinch analysis, mathematical modelling, and optimization). He has published 45 ISI and 37 Scopus indexed articles to date. He has been extensively involved in research projects and industrial-based projects to assist those companies identifying energy saving opportunities worth millions of dollars through the use of process integration and process systems engineering approach.

1. Introduction

1.1 What is pinch analysis?

1.2 Historical development and industrial experience

1.3 Why does pinch analysis work?

1.4 The concept of process synthesis

1.5 Hierarchy of energy reduction

1.6 The role of thermodynamics in process design

1.7 Learning and applying the techniques

1.8 A note on terminology

2. Carbon footprint and primary energy

2.1 Introduction

2.2 Definition of carbon footprint

2.3 Primary energy

2.4 Carbon dioxide emissions and carbon footprint

2.5 Components of carbon footprint

2.6 Carbon pinch and emissions targeting

2.7 Energy costs

2.8 Conclusions

3. Key concepts of pinch analysis

3.1 Heat recovery and heat exchange

3.2 The pinch and its significance

3.3 Heat exchanger network design

3.4 Choosing ?Tmin: supertargeting

3.5 Methodology of pinch analysis

3.6 Worked exercise

4. Data extraction and energy targeting

4.1 Data extraction

4.2 Case study - organics distillation plant

4.3 Energy targeting

4.4 Multiple utilities

4.5 More advanced energy targeting

4.6 Targeting heat exchange units, area and shells

4.7 Supertargeting; cost targeting for optimal ?Tmin

4.8 Targeting for organics distillation plant case study

4.9 Exercises

Appendix – Algorithms for Problem Table and composite curves

5. Heat exchanger network design

5.1 Introduction

5.2 Heat exchange equipment

5.3 Stream splitting and cyclic matching

5.4 Network relaxation

5.5 More complex designs

5.6 Multiple pinches and near-pinches

5.7 Retrofit design

5.8 Operability; multiple base case design

5.9 Network design for organics distillation case study

5.10 Conclusions

5.11 Exercises

6. Utilities, heat and power systems

6.1 Concepts

6.2 Combined heat and power systems

6.3 Heat pumps and refrigeration systems

6.4 Total site analysis

6.5 Worked example – organics distillation unit

6.6 Worked case study and example for total site problem table algorithm

6.7 Case studies and examples

6.8 Exercises

7. Process change and evolution

7.1 Concepts

7.2 General principles

7.3 Reactor systems

7.4 Distillation columns

7.5 Evaporator systems

7.6 Flash systems

7.7 Solids drying

7.8 Other separation methods

7.9 Application to the organics distillation process case study

7.10 Summary and conclusions

7.11 Exercises

8. Batch and time-dependent processes

8.1 Introduction

8.2 Concepts

8.3 Types of streams in batch processes

8.4 Time intervals

8.5 Calculating energy targets

8.6 Heat exchanger network design

8.7 Rescheduling

8.8 Debottlenecking

8.9 Other time-dependent applications

8.10 Conclusions

9. Water, hydrogen, and carbon pinch

9.1 Introduction

9.2 Concepts

9.3 Key steps in mass pinch analysis

9.4 Application and case study for water pinch analysis (Glove Industry)

9.5 Application and case study for hydrogen pinch analysis

9.6 Conclusions for water and hydrogen pinch analysis

9.7 Carbon pinch

10. Applying the technology in practice

10.1 Introduction

10.2 How to do a pinch study

10.3 Heat and mass balance

10.4 Stream data extraction

10.5 Targeting and network design

10.6 Project evaluation and costing

10.7 Targeting software

10.8 Exercises

11. Industrial experience

11.1 Overview

11.2 Oil refining

11.3 Bulk chemicals – continuous

11.4 Speciality and batch chemicals and pharmaceuticals

11.5 Pulp and paper

11.6 Food and beverage

11.7 Consumer products and textiles

11.8 Minerals and metals

11.9 Heat and power utilities

11.10 Buildings

11.11 Waste processing and sewage

12. Case studies

12.1 Introduction

12.2 Crude preheat train

12.3 Aromatics plant

12.4 Evaporator/dryer plant

12.5 Organic chemicals manufacturing site

12.6 Food processing plant

12.7 Hospital site

12.8 Conclusions

12.9 Exercises

13. Conclusions

Notation

Further reading

Appendix 1. Using the spreadsheet software

Appendix 2. Answers to selected exercises

Index