A simulation tool for pinch analysis and heat exchanger/heat pump integration in industrial processes: Development and application in challenge-based learning

Abstract

A novel simulation tool for pinch analysis and heat exchanger/heat pump integration has been developed and tested on a variety of process problems. The tool enables users to efficiently solve problems of varying complexity that would be cumbersome to address manually, thus, aligning with industrial practice where engineers rely on commercial software to streamline analysis and design processes. Demonstrations using the tool show that it can accurately produce composite and grand composite curves and compute heating/cooling utility targets, heat recovery targets and pinch points, for any given process data. It can also determine heat exchanger networks that realise these targets. A key distinguishing feature of the tool is its integration of Heat Pumps, which is particularly relevant given the growing trend toward the electrification of heat in industrial systems. Through several case studies, students applied the tool to optimise process energy systems, demonstrating its potential to enhance learning outcomes while providing valuable insights into energy efficiency and decarbonisation strategies. Applied in an industrial decarbonisation challenge in collaboration with a food manufacturer, the tool generates heat exchanger and heat pump integration solutions resulting in significant energy savings—up to 48 % in heating utilities and 100 % in cooling utilities. Overall, the simulation tool effectively bridges the gap between academic learning and industry practice, offering a unique and impactful approach to sustainability education.