Heat Recovery (Pinch) Analysis Services
The target is to operate a process at required throughput and product quality with minimum energy, resource requirements and emissions. In industry, often more than half of the energy is used for heating and cooling processes. It is therefore important to analyze these processes more closely and optimize them in terms of energy consumption, (CO2) emissions, as well as investment and operating costs. Classical energy optimization approaches focus on improving individual apparatuses or infrastructure facilities. Experience shows, however, that a greater overall increase in energy efficiency can usually be achieved by optimally linking energy flows in the overall system. To increase energy efficiency, heat recovery back into the process is essential.
The Pinch analysis systematically examines the entire system (process, production plant, and energy supply). Then, a technically feasible and economically optimized plant design is generated (considering investment and operating costs).
With the recommended measures, the energy requirements of industrial processes can be reduced by 10% to 40%. The payback period is generally one to four years.
Pinch analysis is also a valuable tool when planning new systems/plants and processes ⇒ “First Time Right!"
- Energy savings of 10-40%
- Significant CO2-reduction
- Payback of 1-4 years
- Strong ROI, positive NPV
- Production plants with thermal processes (continuous or batch)
- Planning of new plants and retrofit
- Heating and cooling tasks at different temperature levels
- Annual costs for thermal energy over about 200’000 EUR
- How big is the necessary energy demand (requirement?), if a completely energy-optimized process would be given?
- Where is the economic optimum regarding investment and operating costs?
- How can this optimal condition be achieved?
- Which energy supply is optimal for the entire system (steam boiler, heat pump, combined heat and power unit, etc.)?
- Is the existing energy supply optimally integrated into the system?
- Information on the absolute energy and CO2 saving potential
- Optimal and "realistic" measures for optimized heat recovery and energy supply
- "Correct" integration of HP, CHP etc. into industrial processes
- Catalogue of measures with technical/economic assessment (costs, benefits, payback)
- Strategic planning of the implementation of measures
- Data extraction
- Process analysis, energy and mass balances
- Drawing of energy flow diagram and P&ID
- Creation of an energy stream table of all relevant energy streams
- Questioning process conditions
- Define process requirements
- Define perimeter of the Pinch analysis
- Pinch analysis
- Modelling of energy streams with Pinch software
- Composite Curves
- Targeting
- Heat exchanger network
- List of measures with economical indicators
- Verification of technical and economic feasibility of the measures
- (Iterative adaption of the heat exchanger network)
- Packages of measures recommended for implementation incl. prioritization
