Pinch Analysis Research Articles

Dual-Battery Energy Storage System Targeting using Dual Battery Power Pinch Analysis

Dual-Battery Energy Storage System Targeting using Dual Battery Power Pinch Analysis

Plan Durable Carbon Dioxide Removal with Pinch Analysis

Plan Durable Carbon Dioxide Removal with Pinch Analysis

Design and Development of Integrated Direct Air Capture and Methanation Processes

AbstractThe synergies from integrating direct air capture and CO2 methanation are assessed and quantified. Three direct air capture and methanation processes with different integration strategies are proposed: only heat integration, direct air capture sorbent regeneration with high‐pressure H2, and complete integration in a single unit. The heat integration study via pinch analysis evaluated the potential energy demand reduction. Overall autothermal operation is achievable, as the heat generated in methanation often exceeds that required for direct air capture sorbent regeneration. A novel process combining CO2 adsorption and methanation in one reactor provided the best productivity and energy demand results. However, this design requires complex cycles and strict demands on the sorbent and catalyst, requiring further development and experimental demonstration.

Thermal Integration in Sugar Production Using Pinch Analysis

Objective: the objective of this study is to conceptualize a network of heat exchangers designed to minimize energy waste and enhance the overall efficiency of the sugar production system.Methods: a systematic approach was adopted to analyze energy flows within the plant, identifying key areas for improvement, particularly in heating and evaporation processes. Heat accumulations in cascades and graphical analyses of composite curves were developed using specialized software to optimize heat exchange.Results: the results indicate a significant potential for energy savings, reducing the consumption of cooling and heating utilities in the plant by 7% and 30%, respectively. The developed computational tool allows for energy integration from simple processes to those with hundreds of streams. The pinch technology concept estimated an annual total savings of $464,850.08 in the selected process.Conclusion: this study demonstrates that thermal integration through pinch analysis not only improves energy efficiency in the sugar industry but also contributes to a considerable reduction in operational costs and environmental impact, providing a valuable tool for the industry’s sustainability and competitiveness.

Process integration and electrification through multiple heat pumps using a Lorenz efficiency approach

This paper introduces a novel method for targeting the minimum shaft work required for process electrification employing principles of Pinch Analysis and detailed heat pump performance estimations. The method deviates from conventional Pinch Analysis by dividing the grand composite curve (GCC) into net heat sink and source profiles to enable the placement of heat pumps exploiting the heat pockets of the GCC. Additionally, it employs Lorenz efficiency over exergy efficiency, offering an accurate description of heat pump performance and highlighting the importance of integration between processes. The method is applied to two case studies. The first case, milk evaporator, focused on the placement of heat pumps in the heat pockets of the GCC. The results showed that while the maximum direct heat recovery was 20,447 kW, the optimal configuration limited the heat recovery to 12,199 kW, reducing the shaft work from 1,930 kW to 1,010 kW. The second, a spray dryer case, focused on the integration of electric boilers and the partial process electrification when available excess heat is limited. In this case, 1,520 kW out of 4,640 kW were covered by an electric boiler, with a biomass boiler replacing the electric boiler to cover 3,570 kW if available.

Comprehensive techno-economic and environmental assessment for 2,3-butanediol production from bread waste

Bread waste (BW) is a common food waste in Europe and North America and has enormous potential as a biorefinery substrate for the sustainable synthesis of various platform chemicals. Our previous work made use of BW for the fermentative production of 2,3–butanediol (BDO). The present work evaluated the economic prospects and environmental consequences associated with the overall processes, handling 100 metric tons BW per day. The comprehensive process design using Aspen Plus and integrated techno-economic and environmental assessment was carried out for two different BW hydrolysis scenarios: acid and enzyme hydrolysis, followed by fermentation and extraction-based downstream BDO separation. The optimal heat exchanger network was designed using pinch analysis, which improved the energy efficiency of the process significantly, with about 10 % savings of BDO production costs. Despite this improvement, the BDO derived from BW was exorbitant (4.2–6.9 $/kg) compared to the market price (3.23 $/kg) due to relatively higher capital investment for the current plant capacity. Further, the process inventory was modelled in SimaPro v9.1.0 to estimate the environmental consequences of these production processes for impact categories, such as global warming (2.63 – 3.19 kg CO2 eq.), marine eutrophication (3.55 × 10-4 – 4.01 × 10-4 kg N eq.), terrestrial ecotoxicity (6.44 – 7.88 kg 1,4 − DCB), etc. Sensitivity and uncertainty analyses were also conducted to establish the reliability of the results. It was found that the enzyme hydrolysis was associated with lower environmental impacts than acid hydrolysis. This comprehensive study can be used as a guideline for developing sustainable BW-based biorefinery in the future.

Process Integration Technique for Targeting Carbon Credit Price Subsidy

Mitigating climate change requires a portfolio of strategies and the use of carbon dioxide removal techniques or negative emissions technologies (NETs) will be necessary to achieve to achieve this goal. However, the high implementation costs of advanced NETs lead to expensive carbon credits, hindering their broad acceptance and use. One potential solution involves governmental support through subsidies, aiming to boost the availability of NET-derived carbon credits. This research uses a graphical technique based on an extension of pinch analysis to identify the ideal subsidy level for carbon dioxide removal, taking into account factors such as carbon pricing, supply, and demand. The proposed approach modifies the limiting composite curve (LCC) methodology to accurately determine the optimal subsidy and establish the baseline amount of subsidized carbon dioxide removal needed. The approach enables the convenient and efficient construction of the LCC using a composite table algorithm. To illustrate the proposed methodology, two case studies composed of different NETs and demand sectors are investigated. The results show the most advantageous subsidy levels for these technologies, providing valuable insights to guide policymakers and investors in their decarbonization efforts. This research contributes to the development of effective governance and investment strategies by optimizing NET subsidy allocation. Such optimization is crucial for facilitating the widespread implementation of these technologies, which are in-line with the global efforts to mitigate climate change.

The Application of Pinch Technology to a Novel Closed-Loop Spray Drying System with a Condenser and Reheater.

Spray drying is an energy-intensive process in industrial use, making energy recovery a critical focus for improving overall efficiency. This study investigates the potential of integrating heat-recovery systems, including an innovative air reheater, into a closed-loop spray-drying unit to maximise energy savings. Through detailed pinch analysis, the system achieved a very low approach temperature, averaging 3.48 K, which is significantly lower than that of conventional open-loop systems. The study quantifies the energy-recovery potential by demonstrating that the integration of heat-recovery components can reduce the external heating demand by up to 30%. This not only enhances heat-transfer efficiency but also lowers operational costs and reduces the system's environmental impact. The results suggest that closed-loop systems with air reheaters offer a scalable solution for improving energy efficiency across different industrial applications. The research highlights a new paradigm: focusing on latent energy within the system rather than adjusting individual operational variables.

Energy assessment and heat integration of biofuel production from bio-oil produced through fast pyrolysis of sugarcane straw, and its upgrading via hydrotreatment

Sugarcane processing is one of the most important economic activities in Brazil, producing ethanol and sugar for domestic and international markets. Utilising the lignocellulosic residues of this industry, specifically bagasse and straw, would increase the second-generation biofuel production without increasing the sugarcane planted area. Among the processes available, the fast pyrolysis is a thermochemical conversion process that produces mainly bio-oil, a liquid with several advantages over solid biomass, regarding transportation, pumping, storage, and handling. Moreover, the bio-oil can be upgraded to obtain biofuels of higher added-value. Among feasible upgrading technologies, the hydrotreatment is one of the most promising methods for eliminating the reactive functionalities of the bio-oil by removing oxygen or cracking large molecules in the presence of hydrogen; however, this comes at the expense of a significant hydrogen consumption. Thus, the aim of this study is to evaluate the biofuel production through the fast pyrolysis of sugarcane straw, followed by the upgrading of the produced bio-oil via hydrotreatment. The evaluation is carried out by way of energy and mass balances of the processes, performed using the software Aspen Plus. Furthermore, the possibilities of integrating the bio-oil production and upgrading into the conventional ethanol and sugar production process will also be assessed through heat integration, applying the Pinch analysis. Results showed the potential for renewable gasoline and diesel production with yields of 0.086 kg/kg of dry straw and 0.08 kg/kg of dry straw, respectively. Additionally, integrating the pyrolysis process, including the bio-oil upgrading, into the ethanol production process can achieve a liquid fuel production (ethanol, gasoline and diesel) of 2289.8 MJ/t cane, which represents an increase of 29 %, while the surplus electricity increases in 5.3 %, when compared to the conventional ethanol production plant.

A novel optimization framework integrating multiple initialization, automatic topologization and MINLP reduction to accelerate large-scale heat exchanger network synthesis

Ensuring the solution feasibility and achieving an acceptable solution time for the non-deterministic polynomial-time hard (NP-hard) problem of heat exchanger network (HEN) synthesis is still challenging. In this study, we developed a novel optimization framework for efficiently solving large-scale HEN synthesis problems to obtain near global optimal solutions, simultaneously addressing the solution's infeasibility and time. The optimization framework consists of a multiple initial HEN design model (M-INI model), a new distance-based auto structure transformer (A-STR transformer), and a reduced non-linear programming model (R-NLP model). The M-INI model generates various HEN designs based on pinch analysis by varying the minimum approach temperature and the modes of stream splitting and mixing. The A-STR transformer is first proposed to automatically convert various HEN designs into associated superstructure-based topologies as multiple initial starting points for accelerating the solution of the R-NLP model. A strategy for approximating the temperature difference calculation is further applied to reduce the computational loads. Four case studies were conducted using the proposed method to minimize the total annual cost (TAC). The solutions of general cases 1 and 2 are almost equal to the best results in the literature, while the solution time is reduced by 98.7 % and 99.8 %, respectively, which demonstrates the performance of the proposed method. Especially, the method was applied to two practical industrial HEN cases: a large-scale low-grade heat recovery system and a crude distillation unit. The results of large-scale case 3 show that the optimal solution near the global optimal solution only requires 251.7 s. Case 4 includes pre-splitting in scenario A and free splitting in scenario B. Compared to scenario A, the TAC and solution time in scenario B were reduced by 33.9 % and 93.1 %, indicating that the pre-splitting strategy excludes the optimal from the search space. The proposed novel optimization framework demonstrates the efficiency and applicability of handling large-scale HEN synthesis problems. It can also guide engineers in the design of a large-scale HEN with lower costs and effort.

Энергосбережение и оценка энергоэффективности угледобывающего предприятия

The article is devoted to consideration of issues related to assessing the energy efficiency of a coal mining enterprise. Coal mining enterprises are characterized by a large volume of energy intensive ore mining operations. The article presents possible ways of energy saving in the mining industry. During the research, a system of energy efficiency indicators for coal mining enterprises is presented. Materials and methods. The article proposes a system of indicators for coal enterprises based on existing methods and approaches to assessing energy efficiency. Energy consumption dependence graphs, benchmarking, and pinch analysis are considered as a starting point. Results. The study presents a system of energy efficiency indicators for coal mining enterprises. The proposed system has several levels. The existing methods and approaches for assessing this important indicator for industrial enterprises in the coal industry as a whole are considered. The author’s approach to formalizing the system of energy efficiency indicators for coal mining enterprises is proposed. The significance of energy audit as a key assessment measure is indicated and its stages are highlighted. The influencing factors determining energy costs and their reduction for a coal mining enterprise are systematized, barriers preventing the practical implementation of energy saving measures are analyzed. Discussion. The proposed metrics system provides a comprehensive framework for assessing the energy efficiency of coal mining enterprises at various levels. Its flexibility allows it to be applied to the analysis of individual equipment units, production processes, and overall enterprise performance. Its multi-level approach provides a detailed understanding of energy consumption, which allows for informed decision-making to optimize operations. At the equipment level, the metrics system evaluates the energy consumption and efficiency of individual machines and devices. At the production process level, the metrics system analyzes the energy consumption and efficiency of various stages of coal mining. At the enterprise level, the metrics system provides a comprehensive assessment of overall energy efficiency. It takes into account energy consumption at all levels and allows enterprises to compare their performance with each other and with industry benchmarks. Conclusion. Energy efficiency assessment of a coal mining enterprise allows to understand how and where energy is used, where its use can be improved, and how to reduce its costs. To conduct an energy efficiency assessment, the article proposes a system of indicators, highlighting the features of an energy audit. The main advantage of the proposed system of indicators is that it covers a wide range of energy consumption indicators, which are carefully selected and located at different levels of detail. In general, a balanced approach to the level of detail and generalization in the system of indicators provides flexibility in adapting indicators to specific research questions and helps to interpret the results in the context of structural differences between energy systems. Resume. Overall, the proposed metrics system offers a comprehensive approach to analyzing the energy efficiency of coal mining enterprises, covering all levels of operations. Its use allows enterprises to improve energy efficiency, reduce operating costs, and contribute to a more sustainable coal mining industry. Suggestions for practical applications and directions for future research. The use and implementation of the developed system at a coal mining company allows it to improve energy efficiency, reduce operating costs and contribute to a more sustainable coal mining industry.

Blockchain-based concept for total site heat integration: A pinch-based smart contract energy management in industrial symbiosis

Industrial symbiosis has gained prominence in pursuing sustainable industrial practices, aiming to optimise resource utilisation and reduce environmental impacts. A critical aspect of this endeavour is the efficient management of energy resources within an industrial ecosystem. This paper presents a novel approach to enhance Total Site Heat Integration (TSHI) implementations by employing Blockchain as a facilitator for decentralised energy management. TSHI is an efficient and widely applied method for industrial symbiosis concerning energy flows, which employs the steam mains in site utility systems as the platform for exchanging heat between industrial processes at various temperature levels. It is shown that the synergy of Pinch Analysis and Smart Contract technologies is capable of facilitating energy integration of processes belonging to independent market actors, compared with the currently dominant integration inside a single company. The proposed framework leverages Blockchain as a distributed ledger to enable secure, transparent, and automated energy management across multiple industrial entities in an industrial symbiotic network. The integration of Pinch Analysis principles ensures that the Heat Integration process is optimised to improve the overall energy efficiency. Smart contracts enable automatic negotiation and execution of energy transactions based on predefined rules, minimising the time lag for concluding deals on energy resource exchange and conservation. This paper examines several scenarios to illustrate the implementation of the proposed Blockchain-based TSHI concept within an industrial symbiosis network. It is demonstrated that up to 16 % cost savings are possible by simply enabling transparency via Blockchain. The results could drive innovative development to revolutionise decentralised energy management in a complex industrial ecosystem, especially by synchronising energy exchanges in time.

Enhancing the efficiency of power generation through the utilisation of LNG cold energy by a dual-fluid condensation rankine cycle system

As a clean energy source with high calorific value and low pollution, liquefied natural gas (LNG) has gained much attention and increased fast in the current energy market. It also has considerable cold energy resources that can be used to generate electricity during the regasification process. To fully utilise the cold energy of LNG, a double-Rankine cycle power generation system that incorporates heat exchange between LNG cold energy utilisation and a propane-ethylene cycle working medium is proposed and optimised. The optimisation is based on the Process Integration method, which uses Pinch Analysis to develop a Heat Exchange Network. Upon a specified LNG flow rate of 15.6 kg/s and natural gas delivery pressure of 7.85 MPaG, a retrofit case of the optimised LNG cold energy system generates a power of 1917.21 kW. A 28.6 % increase in power generation efficiency compared with the existing case. The result showed that by employing the Process Integration method, this study maximises the use of LNG cold energy through heat exchange with various working media, effectively addressing power generation efficiency issues. This approach is important in reducing power generation costs, minimising environmental impact, and advancing resource sustainability. Furthermore, it serves as a valuable reference for enhancing power generation efficiency by utilising LNG cold energy.

State-of-the-art and challenges of Pinch Analysis in energy systems

State-of-the-art and challenges of Pinch Analysis in energy systems

Advancing Industrial Process Electrification and Heat Pump Integration with New Exergy Pinch Analysis Targeting Techniques

The process integration and electrification concept has significant potential to support the industrial transition to low- and net-zero-carbon process heating. This increasingly essential concept requires an expanded set of process analysis tools to fully comprehend the interplay of heat recovery and process electrification (e.g., heat pumping). In this paper, new Exergy Pinch Analysis tools and methods are proposed that can set lower bound work targets by acutely balancing process heat recovery and heat pumping. As part of the analysis, net energy and exergy load curves enable visualization of energy and exergy surpluses and deficits. As extensions to the grand composite curve in conventional Pinch Analysis, these curves enable examination of different pocket-cutting strategies, revealing their distinct impacts on heat, exergy, and work targets. Demonstrated via case studies on a spray dryer and an evaporator, the exergy analysis targets net shaft-work correctly. In the evaporator case study, the analysis points to the heat recovery pockets playing an essential role in reducing the work target by 25.7%. The findings offer substantial potential for improved industrial energy management, providing a robust framework for engineers to enhance industrial process and energy sustainability.

Simulation and optimization of crude glycerol refining process as a co-product of biodiesel

Glycerol is an essential chemical raw material widely used in industries such as food, pharmaceuticals, cosmetics, tobacco, and textiles. With the increasing production of biodiesel, a considerable amount of crude glycerol co-product is generated. Purification of crude glycerol by separating it from biodiesel co-products can lead to the production of high-purity glycerol, thus enabling the synthesis of high-value-added chemicals to reduce the production cost of biodiesel. This paper proposes a new glycerol purification process based on the acidification of potassium oleate soap using sulphuric acid. The composition of crude glycerol is complex. The presence of salts can affect the binary interaction parameters of glycerol and water. The ion forms resulting from the ionization of potassium fatty acid soaps are not available in the database and require important data to be provided through physical property estimation. Additionally, the dissociation of sulphuric acid is involved in the system. These issues make it challenging to propose a complete process based on the characteristics of crude glycerol. In this study, the vapor–liquid equilibrium data of the glycerol-water system containing potassium sulphate under reduced pressure were experimentally determined, and the binary interaction parameters of the glycerol-water system were regressed and used in the subsequent process simulation. The entire process of crude glycerol refining from biodiesel co-products was simulated and optimized using Aspen Plus software, proposing an optimized complete refining process for crude glycerol and designing a crude glycerol refining process with a production scale of 100,000 tons per year. The potassium oleate soap is first acidified with sulphuric acid, then removed by centrifugation, with the resulting lower layer entering the distillation process. We compared two different distillation processes and identified the more optimal separation sequence. Glycerol products with a mass concentration of 99.2% were obtained, with glycerol and methanol yields of 98.83% and 99.79%, respectively. Based on the above research, energy integration and optimization of the process were further investigated through pinch analysis. Overall, energy savings of 7.192 Gcal/h were achieved, resulting in a reduction in energy consumption of 40.65%. This paper proposes a new purification scheme for crude glycerol and an energy integration scheme to reduce the purification cost of high-purity glycerol. This is significant for the rational utilization of crude glycerol, a co-product of biodiesel.

Turning Waste into Wealth: A Conceptual Design of Limonene Production Plant from Waste Rubber Tyre

Limonene production represents a compelling opportunity in the global market, given its competitive landscape dominated by a few key players who control nearly half of the industrial-grade limonene market. Due to the high polyisoprene content in vehicle tyres, along with the rising number of waste rubber tyres, the production of limonene by pyrolysis of tyres may represent a future trend to turn waste into wealth. Hence, a conceptual plant design was carried out to determine the feasibility of limonene production from waste rubber tyres in Malaysia. This feasibility study involved Aspen Plus simulation and illustrated the main processes using Process Flow Diagram (PFD), Piping and Instrumentation Diagram (P&ID), and comprehensive stream table integrating material and energy balances. The desired product, which is limonene, was produced by the gas-solid pyrolysis within a conical spouted bed reactor (CSBR) in an inert atmosphere of non-oxidizing, achieving limonene of 98% purity. Besides, process optimization via pinch analysis has been performed to recover 223.84 kWh of energy using heat integration, resulting in 62.06% of energy saving. From the economic analysis conducted, the total capital investment is RM12.9 million and the annual revenue is RM124.7 million with an annual limonene production of 543.1 tons. The financial analysis demonstrated a robust return on investment (ROI) of 303%, a simple payback period of 0.33 years and ta Net Present Value (NPV) of RM 432.2 million.

Combining Exergy and Pinch Analysis for the Operating Mode Optimization of a Steam Turbine Cogeneration Plant in Wonji-Shoa, Ethiopia.

In this research, the simulation of an existing 31.5 MW steam power plant, providing both electricity for the national grid and hot utility for the related sugar factory, was performed by means of ProSimPlus® v. 3.7.6. The purpose of this study is to analyze the steam turbine operating parameters by means of the exergy concept with a pinch-based technique in order to assess the overall energy performance and losses that occur in the power plant. The combined pinch and exergy analysis (CPEA) initially focuses on the depiction of the hot and cold composite curves (HCCCs) of the steam cycle to evaluate the energy and exergy requirements. Based on the minimal approach temperature difference (∆Tlm) required for effective heat transfer, the exergy loss that raises the heat demand (heat duty) for power generation can be quantitatively assessed. The exergy composite curves focus on the potential for fuel saving throughout the cycle with respect to three possible operating modes and evaluates opportunities for heat pumping in the process. Well-established tools, such as balanced exergy composite curves, are used to visualize exergy losses in each process unit and utility heat exchangers. The outcome of the combined exergy-pinch analysis reveals that energy savings of up to 83.44 MW may be realized by lowering exergy destruction in the cogeneration plant according to the operating scenario.

Recovery and utilisation of waste heat for sponge iron process through combined preheating and power generation

This paper deals with an option accounted for total waste gas heat recovered through combined preheating as well as power generation of feed material, kiln air, as well as slinger coal when it reaches 250 °C from 994 °C. The heat recovery is obtained through GCC Profile is plotted using HINT software. The power produced is 2.757 MW with an optimal condition having a temperature of 280 °C saturated, 600 °C superheated, as well as superheated pressure of 350 bar. The heat required around the superheater, boiler and preheater is 5066.9 kW, 12,669.93 kW and 6873.6 kW. The air requirement for this option is 52.588 t/h after iteration. Also, the iterative waste gas flow rate is 22.31 kg/s. Three new heat exchangers are required to achieve possible heat recovery by designing HEN through Pinch Analysis. The water requirement around EC is 14.88 t/h and 7.8 t/h as in the case of actual and modified HEN. The calculated pressure drops of different ducts having lengths 25 m and pressure 0.034 atm, 80 and 105 m are obtained pressure as 0.034, 0.12 and 0.16 atm. 3 FD fans are required for maintenance of required pressures in the duct. The TAC is INR 8068.8/y; payback period is 2.62 y.

A Formulated Method for Streams Splitting in Heat Exchanger Network Design Using Pinch Analysis

Abstract Thermal processes constitute a significant portion of energy consumption in the industrial sector. In this context, pinch analysis has emerged as a powerful method for achieving substantial energy savings. By systematically analyzing process streams and their heat transfer characteristics, pinch analysis enables the identification of heat recovery opportunities, leading to the design of an optimized heat exchanger network that minimizes energy requirements. In this study, a formulated stream splitting method is proposed to design a feasible minimum energy requirement heat exchanger network. This method aims to achieve two main goals. First, it gives a practical formulated method to help the designer when splitting streams and focuses on splitting the streams in such a way that creates sub-streams with the exact enthalpy required to satisfy heat exchanges with a specific number of streams, in order to minimize the need for process-utility heat exchangers whenever possible. Subsequently, the method aims to eliminate exergy destruction caused by temperature differences in the mixer used to recombine the split streams, by ensuring an isothermal mixture of streams, preventing unnecessary energy losses. The design of the heat exchanger network is conducted using the hint software, allowing for a comprehensive and detailed analysis of each step. The results obtained show that the heat exchanger network attained not only achieves the minimum energy consumption but also mitigates exergy destruction and avoids unnecessary process-utility heat exchangers, resulting in enhanced overall system performance.