How Composite Curves and Pinch Analysis are Used to Improve the Energy Efficiency of the Plant? Answering the Key Questions About Composite Curves

Ivana Lukec, Ph.D.
How Composite Curves and Pinch Analysis are Used to Improve the Energy Efficiency of the Plant?

Composite curves are a synonym for the application of pinch technology and improvement of the unit's energy efficiency. Learning how to read them can be of great value in estimating the energy efficiency level of the current plant design. A short tutorial about how to develop and read composite curves is also available in pdf; find the download below.

1. What are composite curves?

Composite curves are T/H diagrams (temperature/heat diagrams) used to visualize cold and hot streams and potential heat transfer between them. It is a graphical technique used for visualizing the heat cascade. 

2. What is the theoretical background for building composite curves?

A helpful method of visualization is the temperature–heat content diagram based on the following equations:

H – the heat content H of a stream, frequently called its enthalpy, kW;
Cp – heat capacity flowrate, kW/K = mass flow w (kg/s) x specific heat cp (kJ/kgK);
TS – supply temperature, ºC
TT – target temperature, ºC
With CP assumed constant, for a stream requiring heating (“cold” stream) from a “supply temperature” (TS) to a “target temperature” (TT), the total heat added will be equal to the stream enthalpy change.
The slope of the line representing the stream is:

This is the theoretical basis for developing composite curves.

3. How composite curves are built in practice?

Let's take a look at the example of 3 hot streams A, B, and C without going into any details of the process. Just to understand how to build one composite curve from different heat streams.


In the graph above, the three hot streams are plotted separately, with their supply and target temperatures defining a series of “interval” temperatures T1–T5. Between T1 and T2, only stream B exists, and so the heat available in this interval is given by B x (T1 - T2). 
Between T2 and T3 all three streams exist and so the heat available in this interval is (A + B) x (T2 – T3) and so on…
A series of values of ΔH for each interval is obtained in this way and the result re-plotted against the interval temperatures as shown in the picture on the right. 

And - we have produced one hot composite curve! In a same way, a cold composite curve is developed. Once we have both of them in a graphic representation, we can look into the information they are providing...


4. Great! So, what can be found out from composite curves?

The figure below is showing a typical pair of composite curves:

The most important information that can be perceived from this pair of composite curves:

  • The overlap between the composite curves represents the maximum amount of heat recovery possible within the process. 
  • The “overshoot” at the bottom of the hot composite represents the minimum amount of external cooling required.
  • The “overshoot” at the top of the cold composite represents the minimum amount of external heating required.
  • The position where two composite curves are the closest to each other represents the pinch point that will define the requirements of how to improve energy efficiency.

5. What does that mean in the real world for a particular plant or section?

Simply put, we can say that composite curves show the potential - energy target – what is possible to achieve: maximum heat recovery possible, the minimum required heating and minimum required cooling. If you compare these numbers with the numbers of the current state of the plant, you will have information on how efficient the plant is in the terms of heater exchangers network and how much the plant can be improved to get the numbers that are closer to the optimal, as given in the analysis. 

A short-cut analysis of a plant or section can be done in 30 minutes. Of course, for deeper, reliable, and robust analysis and a trustworthy solution and correct decision – more time and effort is needed that includes the knowledge of the process, a modeling tool and the focus. 
To learn more about pinch analysis through a short mini-course and to be informed about the interactive course where you can build your solution with the support from the experienced mentor, subscribe with your email at this link.



Ivana is Ph.D. in chemical engineering and works as a process modeling and simulation expert in her family company Model. Through her 15+ years of experience, she has been involved in the execution of projects that include: optimization studies and projects, conceptual and basic design, energy efficiency improvement projects, data-driven models and predictive analytics, advanced process control and operator training simulators as an engineer and later consultant.

Process analysis, development and optimization are her passion in all areas of life and she is very much motivated to transfer her passion for problem-solving to younger engineers. Some of her experiences she is sharing as an instructor at Model Development Courses.

She'd like to see more chemical engineering entrepreneurs who are confident and motivated enough to take responsibility and leadership in creating better and sustainable paths and processes to help environment preservation, pollution minimization and more efficient waste conversion.

Connect with Ivana through her LinkedIn profile.


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