A target-evaluation method for heat exchanger network optimisation with heat transfer enhancement

Abstract Energy conservation and efficiency improvement are critical problems for industrial process systems. Heat exchanger network retrofit has emerged as a powerful tool for energy-saving and Heat Integration, but the topology modification with new heat exchangers and re-piping is expensive and demands a long payback period. In this study, heat transfer enhancement is deployed in the heat exchanger network retrofit to avoid network topology modification. A target-evaluation method is proposed for heat exchanger network retrofit with the consideration of the thermal efficiency and the level of heat transfer enhancement. Two case studies are conducted to demonstrate the proposed method. The energy-saving of case 1 is 10.6752 MW, which is 13.3% of the original utility loads; 8.0303 MW heat loads are saved in case 2, which is 14.7% of the original utility loads. The results of return on investment indicate that enhancement of the best candidate heat exchanger can bring more energy-saving and better economic efficiency with fewer modifications to the existing heat exchangers, which is also confirmed by sensitivity analysis. The lower temperature effectiveness of the heat exchanger shows great potential for thermal efficiency improvement. The present results highlight the energy-saving effects that heat transfer enhancement has on the heat exchanger network retrofit. The proposed two-stage method supports the further development of energy conservation in different industries.

[1]  Mary O. Akpomiemie,et al.  Retrofit of heat exchanger networks without topology modifications and additional heat transfer area , 2015 .

[2]  Ning Mao,et al.  A novel heat exchanger network retrofit approach based on performance reassessment , 2018, Energy Conversion and Management.

[3]  Bohong Wang,et al.  Heat exchanger network retrofit by a shifted retrofit thermodynamic grid diagram-based model and a two-stage approach , 2020 .

[4]  P. Varbanov,et al.  Experimental thermal-hydraulic performances of heat exchangers with different baffle patterns , 2020 .

[5]  Ralph L. Webb,et al.  Heat transfer and friction characteristics of internal helical-rib roughness , 2000 .

[6]  Igor Bulatov,et al.  Application of intensified heat transfer for the retrofit of heat exchanger network , 2012 .

[7]  B. Linnhoff,et al.  Sensitivity tables for the design of flexible processes (1) ― How much contingency in heat exchanger networks is cost-effective? , 1986 .

[9]  Kuppan Thulukkanam.  Heat Exchanger Design Handbook , 2013 .

[10]  U. N. Gaitonde,et al.  Heat transfer and pressure drop characteristics of turbulent flow in a circular tube fitted with regularly spaced twisted-tape elements , 1990 .

[11]  Kitipat Siemanond,et al.  A robust design method for retrofit of industrial heat exchanger networks using modified stage-wise model , 2021 .

[12]  G. T. Polley,et al.  Use of heat transfer enhancement in process integration , 1992 .

[13]  Bohong Wang,et al.  Heat transfer enhancement, intensification and optimisation in heat exchanger network retrofit and operation , 2020 .

[14]  Bodo Linnhoff,et al.  Using pinch technology for process retrofit , 1986 .

[15]  S. Nguang,et al.  Characterization of the Effect of Corrugation Angles on Hydrodynamic and Heat Transfer Performance of Four-Start Spiral Tubes , 2001 .

[16]  Qiuwan Wang,et al.  Performance of SrBr2·6H2O based seasonal thermochemical heat storage in a novel multilayered sieve reactor , 2019, Energy Conversion and Management.

[17]  Ian C. Kemp,et al.  Pinch Analysis and Process Integration: A User Guide on Process Integration for the Efficient Use of Energy , 2007 .

[18]  Petar Sabev Varbanov,et al.  Heat exchanger network retrofit supported by extended Grid Diagram and heat path development , 2015 .

[19]  W. Tao,et al.  A revised performance evaluation method for energy saving effectiveness of heat transfer enhancement techniques , 2019, International Journal of Heat and Mass Transfer.

[20]  Robin Smith,et al.  Heat exchanger network retrofit with a fixed network structure , 2014 .

[21]  A. E. Bergles,et al.  Heat Transfer and Pressure Drop in Tape-Generated Swirl Flow of Single-Phase Water , 1969 .

[22]  N.D.K. Asante,et al.  An Automated and Interactive Approach for Heat Exchanger Network Retrofit , 1997 .

[23]  Nassim Tahouni,et al.  Improving energy efficiency of an Olefin plant – A new approach , 2013 .

[24]  Pongjet Promvonge,et al.  Heat transfer behaviors in a tube with combined conical-ring and twisted-tape insert ☆ , 2007 .

[25]  M. Jensen,et al.  Technical Note Experimental investigation of turbulent heat transfer and fluid flow in internally finned tubes , 1999 .

[26]  Nurdan Yıldırım,et al.  Thermodynamic assessment of downhole heat exchangers for geothermal power generation , 2019, Renewable Energy.

[27]  Robin Smith,et al.  Heat exchanger network retrofit optimization involving heat transfer enhancement , 2012 .

[28]  Petar Sabev Varbanov,et al.  Shifted Retrofit Thermodynamic Diagram: A Modified Tool for Retrofitting Heat Exchanger Networks , 2014 .

[29]  Igor Bulatov,et al.  New insights to implement heat transfer intensification for shell and tube heat exchangers , 2013 .

[30]  D. P. Sekulic,et al.  Fundamentals of Heat Exchanger Design , 2003 .

[31]  Hafiz Muhammad Ali,et al.  Recent advances in application of nanofluids in heat transfer devices: A critical review , 2019, Renewable and Sustainable Energy Reviews.

[32]  René Bañares-Alcántara,et al.  A Novel Visualization Tool for Heat Exchanger Network Retrofit , 1996 .

[33]  Yufei Wang.  Heat exchanger network retrofit through heat transfer enhancement , 2011 .

[34]  Qiuwan Wang,et al.  Review of two types of surface modification on pool boiling enhancement: Passive and active , 2020 .

[35]  Iftekhar A. Karimi,et al.  Simulation-based approach for integrating work within heat exchange networks for sub-ambient processes , 2020 .

[36]  Xiang-long Luo,et al.  Synthesis and simultaneous MINLP optimization of heat exchanger network, steam Rankine cycle, and organic Rankine cycle , 2020 .