Optimal heat exchanger network synthesis with operability and safety considerations

Research on the optimal design of heat exchanger networks (HENs) has primarily revolved around trading off technical design requirements for aspects of economy, such as capital cost of heat exchangers and utilities. As a result, considerations for safety, operability, and flexibility have received much less attention. This study presents a Pinch Analysis-based methodology that considers the inherent safety and operability aspects of an optimal HEN design. The procedure begins with data extraction, followed by utility targeting that gives due consideration to how each process stream impacts the inherent safety of the HEN. This is made possible via the use of a hot and cold Stream Temperature versus Enthalpy Plot (STEP) that prioritises the inherent safety index (ISI) on top of the heat capacity flow rate (CPs) during simultaneous targeting and design of the HEN. The Pinch temperatures and minimum utilities were determined using STEP. At the same time, the hot and cold stream pairs with higher ISIs and those with lower ISIs were matched together so that safety considerations could be emphasised and precautions taken with a particular heat exchanger. The disturbance propagation path through the HEN and the affected streams were also analysed. Network modification was performed using the downstream path concept in order to reduce disturbance propagation downstream of the HEN. The ∆Tmin violations and energy penalties from network changes were assessed. Flexibility and structural controllability of each network option were compared. The highest percentage of change in every stream of the network indicates that network is the most flexible, while the index of structural controllability closest to 1 demonstrates that the network is most controllable. Application of this method within an illustrative case study showed that network 3 was the most flexible as it yielded the highest percentage of change at 22 %. It was also the most controllable as it had a controllability index closest to 1.0, i.e. at 0.917.