Simultaneous synthesis of heat exchanger networks with pressure recovery: optimal integration between heat and work

The optimal integration between heat and work may significantly reduce the energy demand and consequently the process cost. This paper introduces a new mathematical model for the simultaneous synthesis of heat exchanger networks (HENs) in which the pressure levels of the process streams can be adjusted to enhance the heat integration. A superstructure is proposed for the HEN design with pressure recovery, developed via generalized disjunctive programming (GDP) and mixed-integer nonlinear programming (MINLP) formulation. The process conditions (stream temperature and pressure) must be optimized. Furthermore, the approach allows for coupling of the turbines and compressors and selection of the turbines and valves to minimize the total annualized cost, which consists of the operational and capital expenses. The model is tested for its applicability in three case studies, including a cryogenic application. The results indicate that the energy integration reduces the quantity of utilities required, thus decreasing the overall cost.

MINLP Model for the Synthesis of Heat Exchanger Networks with Handling Pressure of Process Streams

This paper introduces a new mathematical model for the simultaneous synthesis of heat exchanger networks (HENs), wherein the handling pressure of process streams is used to enhance the heat integration. The proposed approach combines generalized disjunctive programming (GDP) and mixed-integer nonlinear programming (MINLP) formulation, in order to minimize the total annualized cost composed by operational and capital expenses. A multi-stage superstructure is developed for the HEN synthesis, assuming constant heat capacity flow rates and isothermal mixing, and allowing for streams splits. In this model, the pressure and temperature of streams must be treated as optimization variables, increasing further the complexity and difficulty to solve the problem. In addition, the model allows for coupling of compressors and turbines to save energy. A case study is performed to verify the accuracy of the proposed model. In this example, the optimal integration between the heat and work decreases the need for thermal utilities in the HEN design. As a result, the total annualized cost is also reduced due to the decrease in the operational expenses related to the heating and cooling of the streams.

Retrofit of heat exchanger networks with pressure recovery of process streams at sub-ambient conditions

This paper presents a new mathematical programming model for the retrofit of heat exchanger networks (HENs), wherein the pressure recovery of process streams is conducted to enhance heat integration. Particularly applied to cryogenic processes, HENs retrofit with combined heat and work integration is mainly aimed at reducing the use of expensive cold services. The proposed multi-stage superstructure allows the increment of the existing heat transfer area, as well as the use of new equipment for both heat exchange and pressure manipulation. The pressure recovery of streams is carried out simultaneously with the HEN design, such that the process conditions (streams pressure and temperature) are variables of optimization. The mathematical model is formulated using generalized disjunctive programming (GDP) and is optimized via mixed-integer nonlinear programming (MINLP), through the minimization of the retrofit total annualized cost, considering the turbine and compressor coupling with a helper motor. Three case studies are performed to assess the accuracy of the developed approach, including a real industrial example related to liquefied natural gas (LNG) production. The results show that the pressure recovery of streams is efficient for energy savings and, consequently, for decreasing the HEN retrofit total cost especially in sub-ambient processes.

Simultaneous synthesis of work exchange networks with heat integration

The optimal integration of work and its interaction with heat can represent large energy savings in industrial plants. This paper introduces a new optimization model for the simultaneous synthesis of work exchange networks (WENs), with heat integration for the optimal pressure recovery of process gaseous streams. The proposed approach for the WEN synthesis is analogous to the well-known problem of synthesis of heat exchanger networks (HENs). Thus, there is work exchange between high-pressure (HP) and low-pressure (LP) streams, achieved by pressure manipulation equipment running on common axes. The model allows the use of several units of single-shaft-turbine-compressor (SSTC), as well as stand-alone compressors, turbines and valves. Helper motors and generators are used to respond to any demand and excess of energy. Moreover, between the WEN stages the streams are sent to the HEN to promote thermal recovery, aiming to enhance the work integration. A multi-stage superstructure is proposed to represent the process. The WEN superstructure is optimized in a mixed-integer nonlinear programming (MINLP) formulation and solved with the GAMS software, with the goal of minimizing the total annualized cost. Three examples are conducted to verify the accuracy of the proposed method. In all case studies, the heat integration between WEN stages is essential to improve the pressure recovery, and to reduce the total costs involved in the process.

MINLP Optimization Algorithm for the Synthesis of Heat and Work Exchange Networks

This paper introduces a new optimization model for the simultaneous synthesis of heat and work exchange networks. The work integration is performed in the work exchange network (WEN), while the heat integration is carried out in the heat exchanger network (HEN). In the WEN synthesis, streams at high-pressure (HP) and low-pressure (LP) are subjected to pressure manipulation stages, via turbines and compressors running on common shafts and stand-alone equipment. The model allows the use of several units of single-shaft-turbine-compressor (SSTC), as well as helper motors and generators to respond to any shortage and/or excess of energy, respectively, in the SSTC axes. The heat integration of the streams occurs in the HEN between each WEN stage. Thus, as the inlet and outlet streams temperatures in the HEN are dependent of the WEN design, they must be considered as optimization variables. The proposed multi-stage superstructure is formulated in mixed-integer nonlinear programming (MINLP), in order to minimize the total annualized cost composed by capital and operational expenses. A case study is conducted to verify the accuracy of the proposed approach. The results indicate that the heat integration between the WEN stages is essential to enhance the work integration, and to reduce the total cost of process due the need of a smaller amount of hot and cold utilities.

Desenvolvimento de técnicas de otimização da programação das limpezas de redes de trocadores de calor

Trocadores de calor são equipamentos muito utilizados na indústria de processos com o objetivo de modificar a temperatura e/ou o estado físico de correntes materiais. Uma rede de trocadores de calor pode ser definida como um grupo de trocadores de calor interligados, a fim de reduzir as necessidades de energia de um sistema. No entanto, durante a operação de uma rede, a eficiência térmica dos trocadores de calor diminui devido à deposição. Esse efeito promove o aumento dos custos de combustível e das emissões de carbono. Uma alternativa para mitigar este problema baseia-se no estabelecimento de uma programação das limpezas dos trocadores de calor durante a operação de rede. Este tipo de abordagem ocasiona uma situação na qual ocorre um conflito de escolha: a limpeza de um trocador de calor pode recuperar a sua eficiência térmica, mas implica custos adicionais, tais como, mão-de-obra, produtos químicos, etc. Além disso, durante a limpeza, o trocador de calor tem de ser contornado por uma corrente de by-pass, o que aumenta temporariamente o consumo de energia. Neste contexto, o presente trabalho tem como objetivo explorar diferentes técnicas de otimização envolvendo métodos estocásticos e heurísticos. Com este objetivo foi desenvolvido um conjunto de códigos computacionais integrados que envolvem a simulação pseudo-estacionária do comportamento da rede relacionado com incrustações e a otimização da programação das limpezas deste tipo de sistema. A solução do problema indica os períodos de tempo para a limpeza de cada trocador de calor. Na abordagem estocástica empregada, os parâmetros do algoritmo genético, como probabilidade de crossover e probabilidade de mutação, foram calibrados para o presente problema. A abordagem heurística desenvolvida se deu através da sequência do conjunto de movimentos zero, um e dois. De forma alternativa, desenvolveu-se a metodologia heurística recursiva na qual os conjuntos de movimentos um e dois foram empregados recursivamente. Também foi desenvolvida a abordagem híbrida que consistiu em diferentes combinações da metodologia estocástica e heurística. A análise comparativa entre as metodologias empregadas teve como objetivo avaliar a abordagem mais adequada para o presente problema da programação das limpezas em termos de função objetivo e esforço computacional. O desempenho da abordagem proposta foi explorado através de uma série de exemplos, incluindo uma refinaria real brasileira. Os resultados foram promissores, indicando que as técnicas de otimização analisadas neste trabalho podem ser abordagens interessantes para operações que envolvam redes de trocadores de calor. Dentre as abordagens de otimização analisadas, a metodologia heurística desenvolvida no presente trabalho apresentou os melhores resultados se mostrando competitiva frente às abordagens comparadas da literatura

Uma abordagem matricial para modelagem e simulação de redes de trocadores de calor com aplicações para o gerenciamento da deposição

Uma rede de trocadores de calor pode ser definida como um grupo de trocadores de calor interligados com o objetivo de reduzir a necessidade de energia de um sistema, sendo largamente usada nas indústrias de processos. Entretanto, uma rede está sujeita à deposição, a qual causa um decréscimo na efetividade térmica dos trocadores. Este fenômeno é provocado pelo acúmulo de materiais indesejáveis sobre a superfície de troca térmica. Para compensar a redução de efetividade térmica causada pela deposição, torna-se necessário um aumento no consumo de utilidades. Isto eleva os custos de operação, assim como os custos de manutenção. Estima-se que os custos associados à deposição atinjam bilhões de dólares anualmente. Em face a este problema, vários trabalhos de pesquisa têm investigado métodos para prevenir a deposição e/ou gerenciar as operações em uma rede. Estudos envolvem desde a otimização de trocadores de calor individuais, simulação e monitoramento de redes, até a otimização da programação das paradas para limpeza de trocadores de calor em uma rede. O presente trabalho apresenta a proposição de um modelo para simulação de redes de trocadores de calor com aplicações no gerenciamento da deposição. Como conseqüência, foi desenvolvido um conjunto de códigos computacionais integrados, envolvendo a simulação estacionária de redes, a simulação pseudo-estacionária do comportamento de redes em relação à evolução da deposição, a estimação de parâmetros para diagnóstico do problema da deposição e a otimização operacional deste tipo de sistema. Com relação ao simulador estacionário, o modelo da rede foi formulado matricialmente e os balanços de massa e energia são resolvidos como sistemas de equações lineares. Do ponto de vista da otimização, o procedimento proposto redistribui as vazões, visando um melhor aproveitamento térmico dos trocadores da rede, como, por exemplo, buscando as vazões da rede que maximizem a temperatura da corrente de entrada no forno em unidades de destilação atmosférica de óleo cru. Os algoritmos foram implementados em alguns exemplos da literatura e em um problema de uma refinaria real. Os resultados foram promissores, o que sugere que a proposta deste trabalho pode vir a ser uma abordagem interessante para operações envolvendo redes de trocadores de calor

Deposition of hydroxyapatite and calcium oxalate dihydrate on a heat exchanger tube

Most studies on the characterisation of deposits on heat exchangers have been based on bulk analysis, neglecting the fine structural features and the compositional profiles of layered deposits. Attempts have been made to fully characterise a fouled stainless steel tube obtained from a quintuple Roberts evaporator of a sugar factory using X-ray diffraction and scanning electron microscopy techniques. The deposit contains three layers at the bottom of the tube and two layers on the other sections and is composed of hydroxyapatite, calcium oxalate dihydrate and an amorphous material. The proportions of these phases varied along the tube height. Energy-dispersive spectroscopy and XRD analysis on the surfaces of the outermost and innermost layers showed that hydroxyapatite was the major phase attached to the tube wall, while calcium oxalate dihydrate (with pits and voids) was the major phase on the juice side. Elemental mapping of the cross-sections of the deposit revealed the presence of a mineral, Si-Mg-Al-Fe-O, which is probably a silicate mineral. Reasons for the defects in the oxalate crystal surfaces, the differences in the crystal size distribution from bottom to the top of the tube and the composite fouling process have been postulated.

CFD simulations of flow and heat transfer through the porous interface of a metal foam heat exchanger

This paper offers numerical modelling of a waste heat recovery system. A thin layer of metal foam is attached to a cold plate to absorb heat from hot gases leaving the system. The heat transferred from the exhaust gas is then transferred to a cold liquid flowing in a secondary loop. Two different foam PPI (Pores Per Inch) values are examined over a range of fluid velocities. Numerical results are then compared to both experimental data and theoretical results available in the literature. Challenges in getting the simulation results to match those of the experiments are addressed and discussed in detail. In particular, interface boundary conditions specified between a porous layer and a fluid layer are investigated. While physically one expects much lower fluid velocity in the pores compared to that of free flow, capturing this sharp gradient at the interface can add to the difficulties of numerical simulation. The existing models in the literature are modified by considering the pressure gradient inside and outside the foam. Comparisons against the numerical modelling are presented. Finally, based on experimentally-validated numerical results, thermo-hydraulic performance of foam heat exchangers as waste heat recovery units is discussed with the main goal of reducing the excess pressure drop and maximising the amount of heat that can be recovered from the hot gas stream.

Hampson type heat-exchanger technology and economic evaluation for LNG re- gasification and power generation At LNG receiving terminals

The system for high utilization of LNG cold energy is proposed by use of process simulator. The proposed design is a closed loop system, and composed by a Hampson type heat exchanger, turbines, pumps and advanced humid air turbine (AHAT) or Gas turbine combined cycle (GTCC). Its heat sources are Boil-off gas and cooling water for AHAT or GTCC. The higher cold exergy recovery to power can be about 38 to 56% as compared to the existing cold power generation of about 20% with a Rankine cycle of a single component. The advantage of the proposed system is to reduce the number of heat exchangers. Furthermore, the environmental impact is minimized because the proposed design is a closed loop system. A life cycle comparative cost is calculated to demonstrate feasibility of the proposed design. The development of the Hampson type exchangers is expected to meet the key functional requirements and will result in much higher LNG cold exergy recovery and the overall system performance i.e. re-gasification. Additionally, the proposed design is expected to provide flexibility to meet different gas pressure suited for the deregulation of energy system in Japan and higher reliability for an integrated boil-off gas system.

Performance assessment in a heat exchanger tube fitted with double counter twisted tape inserts

The present study explored the effects of the double counter twisted tapes on heat transfer and fluid friction characteristics in a heat exchanger tube. The double counter twisted tapes were used as counter-swirl flow generators in the test section. The experiments were performed with double counter twisted tapes of four different twist ratios (y = 1.95, 3.85, 5.92 and 7.75) using air as the testing fluid in a circular tube turbulent flow regime where the Reynolds number was varied from 6950 to 50,050. The experimental results demonstrated that the Nusselt number, friction factor and thermal enhancement efficiency were increased with decreasing twist ratio. The results also revealed that the heat transfer rate in the tube fitted with double counter twisted tape was significantly increased with corresponding increase in pressure drop. In the range of the present work, heat transfer rate and friction factor were obtained to be around 60 to 240% and 91 to 286% higher than those of the plain tube values, respectively. The maximum thermal enhancement efficiency of 1.34 was achieved by the use of double counter twisted tapes at constant blower power. In addition, the empirical correlations for the Nusselt number, friction factor and thermal enhancement efficiency were also developed, based on the experimental data.

Effects of heat exchanger design on the performance of a solid state hydrogen storage device

Heat exchanger design plays a significant role in the performance of solid state hydrogen storage device. In the present study, a cylindrical hydrogen storage device with an embedded annular heat exchanger tube with radial circular copper fins, is considered. A 3-D mathematical model of the storage device is developed to investigate the sorption performance of metal hydride (MH). A prototype of the device is fabricated for 1 kg of MH alloy, LaNi5, and tested at constant supply pressure of hydrogen, validating the simulation results. Absorption characteristics of storage device have been examined by varying different operating parameters such as hydrogen supply pressure and cooling fluid temperature and velocity. Absorption process is completed in 18 min when these parameters are 15 bar, 298 K and 1 m/s respectively. A study of geometric parameters of copper fins (such as perforation, number and thickness of fin) has been carried out to investigate their effects on absorption process. Copyright (C) 2015, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights reserved.