This paper presents a flexible HEN (heat exchanger network) synthesis methodology for designing a multiperiod HEN with streams involving phase changes. The methodology is based on an MINLP (mixed integer nonlinear programming) model, identification of critical points, and flexibility index analysis considering phase changes. A nominal multiperiod HEN topology is constructed in the first step. Then each process operating condition’s critical points and flexibility index are calculated to verify the feasibility of the designed HEN under multiple operating conditions. To verify the validity of the method, the proposed methodology will be applied to a case study on an ammonia synthesis process heat transfer network design based on renewable energy. The results show that the method can obtain a flexible heat transfer network that is cost-effective and adaptable to multi-condition production for green ammonia synthesis.

The non-structural model of heat exchanger networks (HENs) offers a wide solution space for optimization due to the random matching of hot and cold streams. However, this stochastic matching can sometimes result in infeasible structures, leading to inefficient optimization. To address this issue, a tabu matching based on a heuristic algorithm for HENs is proposed. The proposed tabu-matching method involves three main steps: First, the critical temperature levels—high, medium, and low-temperature intervals—are determined based on the inlet and outlet temperatures of streams. Second, the number of nodes is set according to the temperature intervals. Third, the nodes of streams are flexibly matched within the tabu rules: the low-temperature interval of hot streams with the high-temperature interval of cold streams; the streams crossing cannot be matched. The results revealed that by incorporating the tabu rules and adjusting the number of nodes, the ratio of the feasible zone in the whole... [more]

Pinch analysis is vital in optimizing heat exchanger networks (HENs). Targeting methods are used when determining cost effectiveness with pinch analysis. However, the existing targeting methods for the capital cost of HEN are not suitable for wide application scenarios. Therefore, we developed a high-accuracy general capital-cost-targeting method. It is built on a final structure that was evolved from the spaghetti structure of HEN through four loop elimination stages. This structure helps to reduce the prediction deviation of the method. To achieve high adaptability while establishing this method, we considered the different heat exchanger cost categories, different cost laws for one stream pair, and area limitations of heat exchangers that may be encountered in practice. In addition, allowing streams to use individual temperature difference contributions enhances the method’s predictive capacity. The potential defects of the method found in numerical experiments and case studies were... [more]

The non-structural model of a heat exchanger network randomly selects a position of a node on hot and cold streams to generate a heat exchanger and an existing heat exchanger to participate in the evolution. Despite the model being more random and flexible, this selection method cannot easily find a good solution. In addition, the heat exchangers participating in the evolution might not be involved in all streams in each evolutionary process. A stream that does not participate in the evolution will have no significance to the current iteration. Therefore, many iterations are required to make each stream participate in the evolution, which limits the evolution efficiency of the optimization algorithm. In view of this shortcoming, this study proposes a participatory evolutionary strategy for streams based on hot streams. The proposed strategy reorders the existing heat exchangers on hot and cold streams and takes the corresponding measures to ensure that a heat exchanger is selected for... [more]

This work presents the synthesis of heat-integrated water networks (HIWNs) by using mathematical programming. A new superstructure is synthesised by combining a water network and a modified heat exchanger network. Based on the proposed superstructure, a mixed-integer nonlinear programming (MINLP) model is developed. The model is solved by using a one-step solution strategy enabling different initialisations and the generation of multiple solutions, from which the best one is chosen. The results show that the proposed model can be effectively used for solving HIWN problems of different complexities, including large-scale problems.

Reactive dyeing is primarily used in the textile industry to achieve a high level of productivity for high-quality products. This method requires heating a large amount of freshwater for dyeing and cooling for the biological treatment of discharged wastewater. If the heat of the wastewater discharged from the textile industry is recovered, energy used for heating freshwater and cooling wastewater can be significantly reduced. However, the energy efficiency of this industry remains low, owing to the limited use of waste heat. Hence, this study suggested a cost-optimal heat exchanger network (HEN) in a heat pump-assisted textile industry wastewater heat recovery system with maximizing energy efficiency simultaneously. A novel two-step approach was suggested to develop the optimal HEN in heat pump-assisted textile industry wastewater heat recovery system. In the first step, the system was designed to integrate the heat exchanger and heat pump to recover waste heat effectively. In the seco... [more]

A heat integration optimization method that considers the changes in process parameters is proposed to find the global optimal process scheme for a coal chemical company’s phenols and ammonia recovery process. The phenols and ammonia recovery process is simulated by Aspen Plus, and a programming method for heat exchanger networks synthesis that can simultaneously optimize process parameters and heat integration is constructed by Matlab. Taking the total annual cost as the objective function, the following process parameters are optimized: the hot feed temperature and cold/hot feed ratio of sour water stripper, the temperature of three-step partial condensation system, the feed temperature and column pressure of both solvent distillation column and solvent stripper. The result shows that, compared with the heat integration process under original process parameters, the new heat integration process saves 14.3% energy consumption and reduces the total annual cost by about 15.1%. The new h... [more]

In the petroleum industry, naphtha cracking centers (NCC), which produce ethylene, propylene, propane, and mixed-C4, are known to consume a large amount of energy and release a significant amount of carbon dioxide (CO2). This necessitates economic and environmental assessments with the aim of achieving a reduction in energy use in order to ensure efficiency in terms of cost and environmental impact. Herein, a heat exchanger network (HEN) is considered with the aim of determining its optimal operating strategy. In addition, the trade-off between reduction in utility costs (i.e., profit) and the installation cost of the heat exchanger (i.e., loss) is evaluated in terms of economic efficiency. Finally, an environmental impact assessment is performed with respect to the source of fuel consumed for steam generation. The HEN’s energy consumption in the three configurations analyzed herein was found to be reduced by 3%, 6%, and 8%. When considering variations in the fuel used for steam genera... [more]

Facing the current energy structure urgently needs to be transformed, heat exchanger network (HEN) can implement heat recovery and cost reduction by the arrangement for heat exchanges between cold and hot streams. The plenty of integer and continuous variables involved in HEN synthesis cause the results to be easily trapped in local optima. To avoid this situation, the mechanism of accepting imperfect solutions is added in a novel algorithm called Random Walk Algorithm with Compulsive Evolution. However, several potential solutions maybe abandoned by accepting imperfect solutions. To maintain the global searching ability, and at the same time, protecting the potential solutions during the optimization process, the limitations of accepting imperfect solutions are investigated in this work, then a back substitution strategy and elite optimization strategy based on algorithm are proposed. The former is to identify and adjust the inferior individuals in long-term stagnation while the latte... [more]

Methanol and ammonia are important chemical materials in the chemical industry. During the production of methanol and ammonia, a large amount of waste heat is released. The waste heat can be used to save energy and reduce CO2 emissions. In this study, pinch analysis is used to design the heat exchanger network (HEN) of pulverized coke (PC) chemical looping gasification coupled with coke-oven gas (COG) to methanol and ammonia (PCCLHG-CGTMA). The heat integration process is accomplished in two ways, as mentioned below. (1) The HENs in each of the three heat exchange units are designed individually; (2) the HENs of the three heat exchange units are treated as a whole and designed simultaneously. Compared to the HEN designed individually, when the HENs are designed as a whole, a total of 112.12 MW of hot and cold utilities are saved. In the HENs designed as a whole, the reduction in operating cost is sufficient to offset the increase in capital cost; the total annual cost (TAC) is reduced... [more]

Distillation is important to chemical processes but it is energy intensive, and its optimization is of great significance to energy savings and emissions reduction. Varying the operating pressures of distillation columns could assist heat integration of distillation columns into the overall process, thereby reducing energy consumption. However, influences of varying column pressures on the energy profiles of the overall process have not been systematically analyzed in previous studies. This paper presents an insightful analysis of heat integration of distillation into the overall process considering the change of operating pressure. Firstly, effects of changing the operating pressure of a distillation column on its own utility requirements and the related process streams are studied. Next, such effects are graphically represented and incorporated into the grand composite curve (GCC). The change tendencies of the GCC, pinch temperature, and total utility consumption are analyzed and pre... [more]

The dynamic control of Heat Exchanger Network is significant for developing energy efficient and safe industrial processes. In this project, the hot stream's inlet temperature is considered uncertain because it is common in industries. The cold stream is bypassed around the heat exchanger. This project aims to track the setpoint temperature of the mixed stream by manipulating the bypass fraction of the cold stream around the Heat Exchanger given uncertainty in the inlet temperature of the hot stream. The control is implemented in Nonlinear Model Predictive Control (NMPC) framework. The uncertainty in the optimal control problem (OCP)is dealt by using scenario tree based approximation as well as affine policy based method. The model of the system considered is based on the first principles model, i.e. dynamic model of shell and tube heat exchanger. The Orthogonal collocation technique is used to discretize the first principles model into the system of algebraic equations. The results... [more]