This project uses pinch analysis techniques for the heat exchanger network design by aspen energy analyzer software focusing on sulfuric acid production plant. The requirement of energy in any processing industry is a most wanted utility. The increasing cost of energy and environmental concerns are forcing industries to look for methods of reducing energy consumption and wastage. As energy is the key for economic growth and is vital to the modern economy, improving energy efficiency is one of the most important methods for cost saving and tackling of climate change. In Awash Melkassa aluminum sulphate and sulfuric acid factory, production of sulfuric acid is one of the most energy intensive processes. The aim of heat exchanger network (HEN) design is to minimize the use of external utilities by increasing energy recovery by transferring of heat from hot process stream to cold process stream applying the principles of the first and second law of thermodynamics. In this study, the problem is threshold problem which requires only cold utility. Energy and economic savings were realized by pinch analysis. In Awash Melkassa aluminum sulphate and sulfuric acid production factory, the amount of cold utility requirement is 167.69KW and it remains constant as ΔTmin varies up to the threshold temperature (13°C), which is the optimum temperature value. The heat exchanger network design resulted in energy savings of 100% for hot utilities, 42.83% for cold utilities and 59.97% from total utility compared with the current energy consumption of the plant. Profitability analysis of the designed HEN was made and found with a payback period and rate of return of 1.92 years and 42.77% respectively. The result of the study shows that design of HEN by pinch analysis for Awash Melkassa sulfuric acid plant with new heat exchanger arrangement proves that energy integration can lead to a minimum energy (utility) consumption, maximum energy recovery and financial savings of the plant.